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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 966 (Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear -- F150) >> In-Vehicle Repair >> Differential Bearings >> Installation

Differential Bearings: Installation

WARNING: This page is about a different car, the 2005 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
  1. Press the left and right differential bearing on the differential assembly.
    1. Position the differential bearings.
    2. Using the special tool, press the differential bearings on the differential assembly.
    Fig 1: Pressing Left And Right Differential Bearing On Differential Assembly
    G03878661Courtesy of FORD MOTOR CO.
  2. Position the special tool and the inner and outer bearing cups in their respective bores.
    1. After placing the inner and outer bearing cups in their respective bores, place the special tool of the inner bearing cup.
    2. Place the special tool on the outer bearing cup.
    3. Install the special tool.
    Fig 2: Positioning Special Tool And Inner And Outer Bearing Cups In Their Respective Bores
    G03878597Courtesy of FORD MOTOR CO.
  3. Tighten the special tool to seat the pinion bearing cups in their bores.
    Fig 3: Tightening Special Tool To Seat Drive Pinion Bearing Cups In Their Bores
    G03878598Courtesy of FORD MOTOR CO.
    4. NOTE: If a feeler gauge of the specification shown can be inserted between a cup and the bottom of its bore at any point around the cup, the cup is not correctly seated.
    Fig 4: Making Sure Differential Pinion Bearing Cups Are Correctly Seated
    G03878664Courtesy of FORD MOTOR CO.
  4. Make sure the differential pinion bearing cups are correctly seated.
    5. 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 5: Assembling And Positioning Drive Pinion Depth Gauge Set
    G03878665Courtesy of FORD MOTOR CO.
  5. Assemble and position the drive pinion depth gauge set.
    1. Position the screw.
    2. Position the aligning adapter.
    3. Position the gauge disc.
    4. Position the gauge block.
    5. Position the inner drive pinion bearing.
    6. Position the outer drive pinion bearing.
    7. Thread on the handle and tighten.
      • Tighten to 2.2 Nm (20 lb-in).
    6. NOTE: The gauge block must be offset to obtain an accurate reading.
    Fig 6: Rotating Gauge Block Several Half Turns To Make Sure Of Correct Seating Of Drive Pinion Bearings
    G03878602Courtesy of FORD MOTOR CO.
  6. Rotate the gauge block several half turns to make sure of correct seating of the drive pinion bearings and position the gauge block.
  7. Install the special tool.
    1. Position the gauge tube and the paper shipping tabs.
    2. Install the differential bearing caps.
    3. Install the 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 gauge block and 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.
    Fig 8: Using Drive Pinion Bearing Adjustment Shim As A Gauge For Drive Pinion Bearing Adjustment Shim Selection
    G03878668Courtesy of FORD MOTOR CO.
  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.
  9. Using the special tool and a shop press, drive the inner drive pinion bearing and 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: Installing New Drive Pinion Collapsible Spacer On Pinion Shaft Against Pinion Shaft Shoulder
    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 tool, install the drive pinion seal.
    Fig 12: Using Special Tool To Install 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.
    Fig 14: Using Special Tool To Hold Pinion Flange While Tightening Pinion Nut
    G03878610Courtesy of FORD MOTOR CO.
  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.
  16. Place the differential carrier assembly with the new differential carrier bearing cups in the axle housing.
    Fig 15: Placing Differential Case In Rear Axle Housing
    G03878552Courtesy of FORD MOTOR CO.
    17. NOTE: Differential bearing shims are to be installed with the chamfer facing outboard.
    Fig 16: Installing Differential Bearing Shim On LH Side
    G03878614Courtesy of FORD MOTOR CO.
  17. Install a differential bearing shim on the LH side.
    18. NOTE: Apply pressure toward the LH side to make sure the left differential bearing cup is seated.
    Fig 17: Installing LH Differential Bearing Cap And Loosely Installing Differential Bearing Cap Bolts
    G03878615Courtesy of FORD MOTOR CO.
  18. Install the LH differential bearing cap and loosely install the differential bearing cap bolts.
  19. Install progressively larger differential bearing shims on the RH side until the largest differential bearing shim selected can be inserted by hand.
    Fig 18: Installing Progressively Larger Differential Bearing Shims On Rh Side Until Largest Differential Bearing Shim Selected Can Be Inserted By Hand
    G03878678Courtesy of FORD MOTOR CO.
  20. Install the RH side differential bearing cap and tighten the differential bearing cap bolts.
    • Tighten to 105 Nm (77 lb-ft).
    Fig 19: Installing RH Side Differential Bearing Cap And Tightening Differential Bearing Cap Bolts
    G03878679Courtesy of FORD MOTOR CO.
  21. Rotate the differential assembly to make sure it rotates freely.
    Fig 20: Rotating Differential Assembly To Make Sure It Rotates Freely
    G03878680Courtesy of FORD MOTOR CO.
  22. Install the special tools and measure the ring gear backlash.
    • If the backlash is within specification, proceed to Step  25.
    • If a zero backlash condition occurs, proceed to Step  23.
    • If the backlash is not within specification, proceed to Step  24.
    Fig 21: Installing Special Tools And Measuring Ring Gear Backlash
    G03878618Courtesy of FORD MOTOR CO.
  23. 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  22.
  24. 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 tables when adjusting the backlash. When the backlash is within specifications, proceed to Step  25.
    BACKLASH ADJUSTMENT & DIFFERENTIAL BEARING SHIM 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
  25. Rotate the differential assembly several times to make sure the differential bearings are seated.
    Fig 22: Rotating Differential Assembly Several Times To Make Sure Differential Bearings Are Seated
    G03878680Courtesy of FORD MOTOR CO.
  26. Using the special tools, recheck the ring gear backlash.
    Fig 23: Using Special Tools To Recheck Ring Gear Backlash
    G03878618Courtesy of FORD MOTOR CO.
  27. Remove the differential bearing cap bolts and differential bearing caps.
    28. NOTE: Differential bearing shims are to be installed with the chamfer facing outboard.
    Fig 24: Identifying Shim Thickness
    G03878619Courtesy of FORD MOTOR CO.
  28. To establish differential bearing preload, increase both LH and RH differential bearing shim sizes as shown.
  29. Using the special tool, fully seat the differential bearing shims. Make sure the assembly rotates freely.
    Fig 25: Using Special Tool To Fully Seat Differential Bearing Shims
    G03878620Courtesy of FORD MOTOR CO.
  30. Install the differential bearing caps and differential bearing cap bolts.
    • Tighten to 105 Nm (77 lb-ft).
    Fig 26: Installing Differential Bearing Caps And Differential Bearing Cap Bolts
    G03878679Courtesy of FORD MOTOR CO.
  31. Using the special tools, recheck the backlash.
  32. Apply marking compound and rotate the differential assembly 5 complete revolutions.
  33. Check and verify an acceptable pattern.
  34. Install the axle shafts. For additional information, refer to AXLE SHAFT .
  35. Position the driveshaft and align the index marks on the pinion flange.
    Fig 27: Positioning Driveshaft And Aligning Index Marks On Pinion Flange
    G03878625Courtesy of FORD MOTOR CO.
    36. 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.
    Fig 28: Installing Driveshaft Flange Bolts
    G03878515Courtesy of FORD MOTOR CO.
  36. Install the driveshaft flange bolts.
    • Tighten to 103 Nm (76 lb-ft).
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