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Axle Assembly: Assembly

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  1. Carry out the DIFFERENTIAL CASE END PLAY CHECK .
  2. Position the inner and outer pinion bearing cups and the special tools in their respective differential housing bores.
    1. After placing the inner and outer pinion bearing cups in their bores, place the special tool (inner) on the inner pinion bearing cup.
    2. Place the special tool (outer) on the outer pinion bearing cup.
    3. Install the special tool.
    Fig 1: Placing Special Tool (Outer) On Outer Pinion Bearing Cup
    G01947986Courtesy of FORD MOTOR CO.
  3. Tighten the special tool to seat the pinion bearing cups into their bores.
    Fig 2: Tightening Special Tool To Seat Pinion Bearing Cups Into Their Bores
    G01947987Courtesy of FORD MOTOR CO.
    4. CAUTION: Always install new pinion bearings when installing new bearing cups.
    NOTE: If the feeler gauge can fit between a cup and the bottom of its bore at any point around the cup, remove and reseat the cup.
    Fig 3: Installing Feeler Gauge Between Cup And Bottom Of Bore
    G01947988Courtesy of FORD MOTOR CO.
  4. Check that the cups have seated correctly in their bores.
    5. CAUTION: If any of the gauge surfaces have nicks in them, remove the high spots with a medium India oilstone to prevent erroneous readings.
    NOTE: Apply only a light oil film on the pinion bearings before assembling the tools.
    Fig 4: Assembling Special Tools (Model 60)
    G01947989Courtesy of FORD MOTOR CO.
    Fig 5: Assembling Special Tools (Model 70)
    G01947990Courtesy of FORD MOTOR CO.
    Fig 6: Assembling Special Tools (Model 70 HD)
    G01947991Courtesy of FORD MOTOR CO.
  5. Assemble and position the following in the differential housing.
    1. Position the special tool.
    2. Position the special tool.
    3. Position the inner pinion bearing.
    4. Position the special tool.
    5. Position the special tool.
    6. Position the outer pinion bearing.
    7. Thread on the special tool.
    6. NOTE: This step simulates pinion bearing preload.
    Fig 7: Tightening Special Tool
    G01947992Courtesy of FORD MOTOR CO.
  6. Using a Nm (inch-pound) torque wrench, tighten the special tool to specification.
    7. NOTE: Offset the special tool as shown to obtain an accurate reading.
    Fig 8: Rotating Special Tool Several Half-Turns
    G01947993Courtesy of FORD MOTOR CO.
  7. Rotate the special tool several half-turns to seat the pinion bearings and position the special tool as shown.
  8. Install the special tool.
    1. Position the special tool.
      • For Model 60/70 axles, use tool 205-D033.
      • For Model 70TR axles, use tool 205-D038.
    2. Install the bearing caps.
    3. Install the bolts.
    Fig 9: Installing Bearing Caps
    G01947994Courtesy of FORD MOTOR CO.
    9. NOTE: Use a feeler gauge or flat, clean drive pinion position shims as a measuring devise.
    NOTE: Do not attempt to force the gauge or shim between the special tools. A slight drag indicates a correct selection.
    Fig 10: Identifying Drive Pinion Position Shims
    G01947995Courtesy of FORD MOTOR CO.
  9. Using a feeler gauge or flat, clean drive pinion position shims, measure between the special tools. Record the measurement. Refer to PINION RING GEAR VARIATION NUMBER  for shim selection information.
    • Remove the special tools after making the correct shim selection.
    10. CAUTION: Follow the drive pinion bearing preload shim and drive pinion position shim assembly sequence as directed or unit failure can result.
  10. Install the correct thickness drive pinion position shim on the pinion.
    11. NOTE: Always use the same new inner pinion bearing installed when taking the measurement for drive pinion shim selection.
    Fig 11: Installing Pinion Bearing
    G01947996Courtesy of FORD MOTOR CO.
  11. Using the special tool, an axle bearing/seal plate, and a suitable press, install the pinion bearing.
    • For Model 60 axles, use tool 205-092.
    • For Model 70 axles, use tool 205-005.
    12. NOTE: Use the thickness of the old drive pinion bearing preload shims as a starting point for setting pinion bearing preload. On Model 70 axles, add the thickness of the pinion preload spacer to the thickness of the old drive pinion bearing preload shims.
    Fig 12: Available Drive Pinion Bearing Preload Shims (Model 60/70)
    G01947997Courtesy of FORD MOTOR CO.
  12. Inspect the drive pinion bearing preload shims for damage. Discard them if necessary. New shims are available in the thickness shown in the following chart.

    13. CAUTION: The pinion preload spacer must always go on the pinion before the drive pinion bearing preload shims.
  13. On Model 70 axles, assemble the pinion preload spacer onto the pinion.
  14. Assemble the drive pinion bearing preload shims onto the pinion, and install the pinion into the differential housing.
  15. Install the outer pinion bearing.
  16. Install the pinion flange.
  17. Use the special tool to prevent the flange from turning while installing the old washer and the lock nut.
    • Tighten the nut to 339 Nm (250 lb-ft).
    Fig 13: Installing Washer And Lock Nut
    G01947998Courtesy of FORD MOTOR CO.
  18. Using an inch-pound torque wrench, rotate the pinion. The torque must read as specified.
    • To increase the preload, remove drive pinion bearing preload shims. To decrease the preload, add shims.
    Fig 14: Checking Drive Pinion Bearing Preload
    G01947999Courtesy of FORD MOTOR CO.
  19. If the pinion bearing preload is within specification, and the pinion position shim has changed, change the drive pinion bearing preload shims by the same amount.
    • The direction arrow pointing toward the pinion flange indicates that by removing the drive pinion position shim, the distance from the centerline of the tubes to the pinion backface increases, giving a plus (+) reading. The drive pinion bearing preload shim pack does not affect the pinion depth setting. However, if the pinion position is changed, the pinion preload will change and may require adjustment to bring the torque-to-rotate within specification. Arrows on the ring gear illustrate the method to increase or decrease backlash and differential bearing preload.
    Fig 15: Checking Pinion Bearing Preload
    G01948000Courtesy of FORD MOTOR CO.
  20. With the drive pinion at the correct preload as determined earlier in this procedure, remove and discard the lock nut and the washer. Use the special tool to prevent the flange from turning.
    Fig 16: Removing Lock Nut And Washer
    G01948001Courtesy of FORD MOTOR CO.
  21. Using the special tool, remove the pinion flange.
    Fig 17: Removing Pinion Flange
    G01948002Courtesy of FORD MOTOR CO.
  22. Lubricate the pinion seal rubber lips.
    • Use Premium Rear Axle Lubricant.
  23. Using a suitable driver, install the pinion seal.
    • After installation, verify that the garter spring did not pop out of the seal. If the garter spring popped out, install a new pinion seal.
    Fig 18: Installing Pinion Seal
    G01948003Courtesy of FORD MOTOR CO.
  24. Coat the inside of the pinion flange with a small amount of lubricant.
    • For Model 60/70 axles, use Premium Rear Axle Lubricant.
  25. Install the pinion flange.
    26. CAUTION: Always install a new washer and lock nut.
    Fig 19: Installing Washer And Lock Nut
    G01948004Courtesy of FORD MOTOR CO.
  26. Use the special tool to prevent the flange from turning while installing the new washer and lock nut.
    • Tighten the nut to 339 Nm (250 lb-ft).
  27. Carry out the RING GEAR AND PINION BACKLASH .
  28. Assemble the differential bearing cups to the differential bearings.
    29. CAUTION: Do not spread the differential housing more than specified.
    CAUTION: Avoid nicking the ring gear teeth and the anti-lock speed sensor ring during assembly.
    Fig 20: Removing Special Tools
    G01948005Courtesy of FORD MOTOR CO.
  29. Using the special tools, spread the differential housing to the specification.
    • Use a rawhide hammer to seat the differential into the differential housing pocket.
      • Remove the special tools.
    30. CAUTION: Match the mating letters as noted during disassembly.
    Fig 21: Installing Bearing Caps
    G01948006Courtesy of FORD MOTOR CO.
  30. Install the bearing caps, aligning the letters with those on the differential housing. Tighten the bolts to specification.
  31. Using the special tools, measure the differential ring gear and pinion backlash at three equally spaced points.
    • The backlash tolerance is 0.13-0.203 mm (0.005-0.008 inch) and cannot vary more than 0.05 mm (0.002 inch) between points checked. A backlash variation of more than 0.05 mm (0.002 inch) indicates gear/case runout.
    • Move the differential ring gear toward the pinion to correct high backlash.
    • Move the differential ring gear away from the pinion to correct low backlash.
    • Moving a specified amount of differential bearing shims from one side of the differential to the other makes these corrections.
    Fig 22: Measuring Differential Ring Gear And Pinion Backlash
    G01948007Courtesy of FORD MOTOR CO.
  32. Confirm the total preload.
    • Using an inch-pound torque wrench, check the torque to rotate the pinion. The reading must be higher than the initial reading (taken without the differential case installed) by the amount shown, with new bearings installed as recommended. See Fig 23.
    • If the total preload is too high, remove an equal amount of differential bearing shims from each differential case hub. If the total preload is too low, add an equal amount of differential bearing shims to each differential case hub.
    Fig 23: Checking Total Preload
    G01948008Courtesy of FORD MOTOR CO.
  33. Carry out the Tooth Contact Pattern Check to verify the final pinion position is correct. For additional information, refer to DRIVELINE SYSTEM-GENERAL INFORMATION .
  34. Install the axle shafts. For additional information, refer to WHEEL HUBS AND BEARINGS - FULL FLOATING AXLE or refer to AXLE SHAFT - SEMI-FLOATING AXLE .
    35. CAUTION: Clean both flat surfaces (differential housing and differential housing cover) with a suitable solvent to remove all traces of oil film.
    CAUTION: Install the differential housing cover within 15 minutes of applying the silicone, or it will be necessary to apply new sealant.
    NOTE: The differential housing cover uses silicone rubber sealant as a gasket.
    Fig 24: Applying Continuous Bead Of Silicone Sealant
    G01948009Courtesy of FORD MOTOR CO.
  35. Apply a continuous bead of silicone sealant, of the specified thickness, to the differential housing cover.
  36. Place two bolts into the differential housing cover at the 8 o'clock 2 o'clock positions. Install the differential housing cover.
    • Use the two bolts to position the differential housing cover on the differential housing.
  37. Install the remaining bolts. Tighten the bolts alternately and evenly.
    • Tighten Grade 5 bolts to 47 Nm (35 lb-ft).
    • Tighten Grade 8 bolts to 61 Nm (45 lb-ft).
    • Allow 1-hour cure time before filling the axle with the correct amount of specified lubricant.
  38. Fill the axle with the specified type and amount of lubricant. For additional information, refer to SPECIFICATIONS .
    Fig 25: Installing Remaining Differential Housing Bolts
    G01948010Courtesy of FORD MOTOR CO.
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