LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 777 (Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear) >> In-Vehicle Repair >> Differential Ring And Pinion >> Installation

Differential Ring And Pinion: Installation

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
  1. Position the special tool and the inner and outer drive pinion bearing cups in their respective bores.
    1. After placing the inner and outer drive pinion bearing cups in their bores, place the special tool (inner) on the inner drive pinion bearing cup.
    2. Place the special tool (outer) on the outer drive pinion bearing cup.
    3. Install the special tool.
      Fig 1: Identifying Special Tool Components
      G03878597Courtesy of FORD MOTOR CO.
  2. Tighten the special tool to seat the drive pinion bearing cups into their bores.
    Fig 2: Tightening Special Tool To Seat Drive Pinion Bearing Cups
    G03878598Courtesy of FORD MOTOR CO.
    3. NOTE: If a feeler gauge can be inserted between a drive pinion bearing cup and the bottom of its bore at any point around the drive pinion bearing cup, the drive pinion bearing cup is not correctly seated.
    Fig 3: Measuring Clearance Between Cup And Bottom Of Its Bore
    G03878599Courtesy of FORD MOTOR CO.
  3. Make sure the drive pinion bearing cups are correctly seated in their bores.
    4. NOTE: Install new drive pinion bearings without any additional lubricant since the anti-rust oil provides adequate lubricant without upsetting the drive pinion bearing preload settings.
    Fig 4: Installing Drive Pinion Bearings
    G03884101Courtesy of FORD MOTOR CO.
  4. Assemble and position the special tools.
    5. NOTE: This step duplicates final drive pinion bearing preload.
  5. Tighten the special tool.
    • Tighten to 2.2 Nm (20 lb-in).
      Fig 5: Checking Differential Pinion Bearing Preload
      G03878601Courtesy of FORD MOTOR CO.
    6. NOTE: The special tool must be offset to obtain an accurate reading.
    Fig 6: Seating Drive Pinion Bearings
    G03878602Courtesy of FORD MOTOR CO.
  6. Rotate the special tool several half-turns to make sure of correct seating of the drive pinion bearings and position the special tool.
  7. Install the special tool.
    1. Position the special tool.
    2. Install the differential bearing caps.
    3. Install the 4 differential bearing cap bolts.
      • Tighten to 105 Nm (77 lb-ft).
        Fig 7: Installing Special Tool
        G03878603Courtesy of FORD MOTOR CO.
    8. NOTE: Drive pinion bearing adjustment shims must be flat and clean.
    NOTE: A slight drag should be felt for correct drive pinion bearing adjustment shim selection. Do not attempt to force the drive pinion bearing adjustment shim between the gauge block and the gauge tube. This will minimize selection of a drive pinion bearing adjustment shim thicker than required, which results in a deep tooth contact in final assembly of integral axle assemblies.
  8. Use a drive pinion bearing adjustment shim as a gauge for drive pinion bearing adjustment shim selection.
    • After the correct drive pinion bearing adjustment shim thickness has been determined, remove all of the special tools.
      Fig 8: Identifying Drive Pinion Bearing Adjustment Shim
      G03878604Courtesy of FORD MOTOR CO.
  9. Using the special tool and a shop press, drive the inner drive pinion bearing and the selected drive pinion bearing adjustment shim until they are firmly seated on the pinion shaft.
    Fig 9: Installing Inner Drive Pinion Bearing
    G03878605Courtesy of FORD MOTOR CO.
  10. Install a new drive pinion collapsible spacer on the pinion shaft against the pinion shaft shoulder.
    Fig 10: Identifying Drive Pinion Collapsible Spacer
    G03878606Courtesy of FORD MOTOR CO.
  11. Install the drive pinion assembly into the axle housing.
    Fig 11: Installing Drive Pinion Assembly Into Axle Housing
    G04583053Courtesy of FORD MOTOR CO.
  12. Install the outer drive pinion bearing and the drive pinion shaft oil slinger.
  13. Using the special tools, install the drive pinion seal.
    Fig 12: Installing Drive Pinion Seal
    G03878608Courtesy of FORD MOTOR CO.
  14. Using the special tools, install the drive pinion flange.
    Fig 13: Installing Drive Pinion Flange
    G03878609Courtesy of FORD MOTOR CO.
    15. CAUTION: Do not, under any circumstance, loosen the drive pinion nut to reduce pinion bearing preload. If it is necessary to reduce the preload, install a new drive pinion collapsible spacer and drive pinion nut.
    CAUTION: Remove the special tool while taking rotational pinion bearing preload checks with the Nm (lb-in) torque wrench.
  15. Use the special tool to hold the pinion flange while tightening the pinion nut.
    • Rotate the pinion occasionally to make sure the differential pinion bearings are seating correctly. Take frequent differential pinion bearing preload checks by rotating the differential pinion with a Nm (lb-in) torque wrench. Tighten the pinion nut in small increments to avoid excessive pinion bearing preload. Tighten the pinion nut until the drive pinion bearing preload is in specification.
      Fig 14: Identifying Pinion Flange Holder
      G03878610Courtesy of FORD MOTOR CO.
  16. Using the special tool, install the new differential bearings.
    Fig 15: Installing Differential Bearings On Differential Case
    G03878611Courtesy of FORD MOTOR CO.
    17. NOTE: Apply stud and bearing mount to the differential ring gear bolts.
  17. Install the differential ring gear bolts.
    • Tighten to 105 Nm (77 lb-ft).
      Fig 16: Identifying Differential Ring Gear Bolts
      G03878612Courtesy of FORD MOTOR CO.
  18. Position the differential carrier assembly and the new differential bearing cups in the differential housing.
    Fig 17: Placing Differential Case In Rear Axle Housing
    G03878552Courtesy of FORD MOTOR CO.
    19. NOTE: Differential bearing shims are to be installed with the chamfer facing outboard.
    Fig 18: Installing Differential Bearing Shim
    G03878614Courtesy of FORD MOTOR CO.
  19. Install a differential bearing shim of the shown in Fig 18 dimension on the left side.
    20. CAUTION: Always install the bearing caps in their original locations and positions.
    NOTE: Apply pressure toward the LH side to make sure the left differential bearing cup seats correctly.
    Fig 19: Identifying LH Differential Bearing Cap
    G03878615Courtesy of FORD MOTOR CO.
  20. Install the LH bearing cap and loosely install the bolts.
  21. Install progressively larger differential bearing shims on the RH side until the largest shim is installed by hand.
    Fig 20: Installing Differential Bearing Shims
    G03878555Courtesy of FORD MOTOR CO.
  22. Install the right side bearing cap and bolts. Tighten the LH and RH bearing cap bolts.
    • Tighten to 105 Nm (77 lb-ft).
  23. Rotate the differential carrier several times to verify the differential bearings have seated correctly.
    Fig 21: Rotating Differential Carrier
    G03878557Courtesy of FORD MOTOR CO.
  24. Install the special tools and measure the ring gear backlash.
    • If the backlash is within specification, proceed to Step  27.
    • If a zero backlash condition occurs, proceed to Step 25.
    • If the backlash is not within specification, proceed to Step  26.
      Fig 22: Measuring Ring Gear Backlash
      G03878618Courtesy of FORD MOTOR CO.
  25. If a zero backlash condition occurs, add 0.50 mm (0.020 in) to the RH side shim and subtract 0.50 mm (0.020 in) from the LH side shim to allow a backlash indication. Go back to Step  24.
  26. To correct for high or low backlash, increase the thickness of one differential bearing shim and decrease the thickness of the other differential bearing shim by the same amount. Refer to the following ITEM SPECIFICATION  when adjusting the backlash. When the backlash is within specification, proceed to Step 27.
    ITEM SPECIFICATION

    Backlash Change Required Thickness Change Required
    mm Inch mm Inch
    0.025 0.001 0.050 0.002
    0.050 0.002 0.050 0.002
    0.076 0.003 0.101 0.004
    0.101 0.004 0.152 0.006
    0.127 0.005 0.152 0.006
    0.152 0.006 0.203 0.008
    0.177 0.007 0.254 0.010
    0.203 0.008 0.254 0.010
    0.228 0.009 0.304 0.012
    0.254 0.010 0.355 0.014
    0.279 0.011 0.355 0.014
    0.304 0.012 0.406 0.016
    0.330 0.013 0.457 0.018
    0.335 0.014 0.457 0.018
    0.381 0.015 0.508 0.020
    DIFFERENTIAL SHIM SIZE CHART 4067

    Stripes and Color Code Dimension A
    mm Inch
    2 - C-COAL 7.7978-7.8105 0.3070-0.3075
    1 - C-COAL 7.7470-7.7597 0.3050-0.3055
    5 - BLU 7.6962-7.7089 0.3030-0.3035
    4 - BLU 7.6454-7.6581 0.3010-0.3015
    3 - BLU 7.5946-7.6073 0.2990-0.2995
    2 - BLU 7.5458-7.5565 0.2970-0.2975
    5 - PINK 7.4422-7.4549 0.2930-0.2935
    4 - PINK 7.3914-7.4041 0.2910-0.2915
    3 - pink 7.3406-7.3533 0.2890-0.2895
    2 - PINK 7.2898-7.3025 0.2870-0.2875
    1 - PINK 7.2390-7.2517 0.2850-0.2855
    5 - GRN 7.1882-7.2009 0.2830-0.2835
    4 - GRN 7.1374-7.1501 0.2810-0.2815
    3 - GRN 7.0866-7.0993 0.2790-0.2795
    2 - GRN 7.0358-7.0485 0.2770-0.2775
    1 - GRN 6.9850-7.0485 0.2750-0.2755
    5 - WH 6.9342-6.9469 0.2730-0.2735
    4 - WH 6.8834-6.8961 0.2710-0.2715
    3 - WH 6.8326-6.8453 0.2690-0.2695
    2 - WH 6.7818-6.7945 0.2670-0.2675
    1 - WH 6.7310-6.7437 0.2650-0.2655
    5 - YEL 6.6802-6.6929 0.2630-0.2635
    4 - YEL 6.6294-6.6421 0.2610-0.2615
    3 - YEL 6.5786-6.5913 0.2590-0.2595
    2 - YEL 6.5278-6.5405 0.2570-0.2575
    1 - YEL 6.4770-6.4897 0.2550-0.2555
    5 - ORNG 6.4262-6.4389 0.2530-0.2535
    4 - ORNG 6.3754-6.3881 0.2510-0.2515
    3 - ORNG 6.3246-6.3373 0.2490-0.2495
    2 - ORNG 6.2738-6.2865 0.2470-0.2475
    1 - ORNG 6.2223-6.2357 0.2450-0.2455
    2 - RED 6.1722-6.1849 0.2430-0.2435
    1 - RED 6.1214-6.1341 0.2410-0.2415
  27. Remove the bearing cap bolts and bearing caps.
    28. NOTE: Differential bearing shims are to be installed with the chamfer facing outboard.
    Fig 23: Identifying Shim Thickness
    G03878619Courtesy of FORD MOTOR CO.
  28. To establish differential bearing preload, increase both LH and RH differential bearing shim size by the thickness shown in Fig 23.
  29. Using the special tool, fully seat the differential bearing shims. Make sure the assembly rotates freely.
    Fig 24: Installing Differential Bearing Shims
    G03878620Courtesy of FORD MOTOR CO.
  30. Install the bearing caps and bolts.
    • Tighten to 105 Nm (77 lb-ft).
      Fig 25: Identifying Bearing Caps And Bolts
      G03878621Courtesy of FORD MOTOR CO.
  31. Using the special tools, recheck the ring gear backlash.
  32. Apply marking compound and rotate the differential assembly 5 complete revolutions.
  33. Check for an acceptable pattern.
  34. Install the axle shafts. For additional information, refer to AXLE SHAFT  in this section.
    35. CAUTION: Make sure the machined surfaces on both the axle housing and the differential housing cover are clean and free of oil before applying the new silicone sealant. The inside of the axle must be covered when cleaning the machined surface to prevent contamination.
  35. Clean the gasket mating surface of the axle and the differential housing cover.
  36. Apply a new, continuous bead of sealant to the differential housing cover.
    Fig 26: Applying A New Continuous Bead Of Sealant To Differential Housing Cover
    G03878622Courtesy of FORD MOTOR CO.
    37. CAUTION: For Traction-Lok® axles, first fill the axle with 118 ml (4 ounces) of friction modifier.
    NOTE: Service refill capacities are determined by filling the axle with the specified lubricant to the specified level below the bottom of the filler hole.
  37. Fill the axle to the level shown in Fig 27 with axle lubricant and install the filler plug.
    • Tighten to 30 Nm (22 lb-ft).
      Fig 27: Checking Axle Lubricant Fill Level
      G03884460Courtesy of FORD MOTOR CO.
  38. Position the driveshaft and align the index marks on the pinion flange.
    Fig 28: Positioning Driveshaft And Align Marks On Pinion Flange
    G03878625Courtesy of FORD MOTOR CO.
    39. CAUTION: The driveshaft centering socket yoke fits tightly on the pinion flange pilot. To make sure that the driveshaft centering socket yoke seats squarely on the pinion flange, tighten the driveshaft flange bolts evenly in a cross pattern.
  39. Install the driveshaft flange bolts.
    • Tighten to 103 Nm (76 lb-ft).
      Fig 29: Identifying Driveshaft Flange Bolts
      G03878515Courtesy of FORD MOTOR CO.
scientia non olet · About LEMON Manuals