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Home >> Ford >> 2002 >> Focus LX, Automatic >> Repair and Diagnosis >> External Pages >> Different car >> Section 669 (Rear Drive Axle/Differential - DANA 80 -- F350 Super Duty) >> Disassembly And Assembly >> Axle Assembly >> Assembly

Axle Assembly: Assembly

WARNING: This page is about a different car, the 2004 Ford Pickup and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: Align the tab on the anti-lock speed sensor ring with the slot in the differential case.
    NOTE: Apply threadlock and sealer to the new bolts.
    Fig 1: Aligning Tab On Anti-Lock Speed Sensor Ring With Slot In Differential Case
    G02768957Courtesy of FORD MOTOR CO.
    Fig 2: Applying Threadlock And Sealer To Bolts
    G02768958Courtesy of FORD MOTOR CO.
  1. Align the tab in the anti-lock speed sensor ring with the slot in the differential case. Start the two bolts through the differential case flange and into the differential ring gear to make sure the differential case and the differential ring gear bolt hole align.
  2. Press the anti-lock speed sensor ring on the differential case. The differential case flange acts as a pilot for the anti-lock speed sensor ring.
    Fig 3: Pressing Anti-Lock Speed Sensor Ring On Differential Case
    G02768959Courtesy of FORD MOTOR CO.
    3. NOTE: Apply threadlock and sealer to the new bolt threads.
    Fig 4: Applying Threadlock And Sealer To Bolt Threads
    G02768960Courtesy of FORD MOTOR CO.
  3. Draw up the Grade 9 bolts alternately and evenly.
  4. Carry out the DIFFERENTIAL CASE END PLAY CHECK .
  5. Position the special tools and the inner and outer pinion bearing cups 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 5: Installing Special Tool
      G02768961Courtesy of FORD MOTOR CO.
  6. Tighten the special tool to seat the pinion bearing cups into their bores.
    Fig 6: Tightening Special Tool To Seat Pinion Bearing Cups Into Bores
    G02768962Courtesy of FORD MOTOR CO.
    7. 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 7: Identifying Feeler Gauge
    G02768963Courtesy of FORD MOTOR CO.
  7. Check that the cups have seated correctly in their bores.
    8. 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.
  8. Assemble and position the following in the differential housing.
    1. Position the screw (adapter for 205-S156).
    2. Position the Alignment Adapter.
    3. Position the inner pinion bearing.
    4. Position the Drive Pinion Depth Gauge/Aligner.
    5. Position the Gauge Block (adapter for 205-S156).
    6. Position the outer pinion bearing.
    7. Thread on the Drive Pinion Depth Gauge/Aligner (Handle).
      Fig 8: Positioning Special Tools
      G02768964Courtesy of FORD MOTOR CO.
    9. NOTE: This step simulates pinion bearing preload.
    Fig 9: Identifying Item Description Chart
    G02768965Courtesy of FORD MOTOR CO.
  9. Using a Nm (inch-pound) torque wrench, tighten the Handle to the specification.
    10. NOTE: Offset the Gauge Block to obtain an accurate reading.
    Fig 10: Positioning Gauge Block
    G02768966Courtesy of FORD MOTOR CO.
  10. Rotate the Gauge Block several half-turns to make sure the pinion bearings are correctly seated and position the Gauge Block.
  11. Install the special tool.
    1. Position the special tool.
    2. Install the bearing caps.
    3. Install the four bolts.
      Fig 11: Installing Special Tool
      G02768967Courtesy of FORD MOTOR CO.
    12. NOTE: Use a feeler gauge or flat, clean drive pinion position shims as a measuring device.
    NOTE: Do not attempt to force the gauge or shim between the Gauge Block and the Gauge Tube. A slight drag indicates a correct selection.
  12. Using a feeler gauge or flat, clean drive pinion position shims, measure between the Gauge Block and the Gauge Tube. Record the measurement. Refer to PINION RING GEAR VARIATION NUMBER .
    • Remove the special tools after making the correct shim selection.
      Fig 12: Measuring Gap Between Gauge Block And Gauge Tube
      G02768968Courtesy of FORD MOTOR CO.
    13. CAUTION: Follow the drive pinion bearing preload shim and drive pinion position shim assembly sequence as directed or unit failure can result.
  13. Install the correct thickness drive pinion position shim, and the oil slinger, if so equipped, on the pinion.
    14. NOTE: Always use the same new inner pinion bearing installed when taking the measurement for drive pinion position shim selection.
    Fig 13: Installing Pinion Bearing Using Special Tool
    G02768969Courtesy of FORD MOTOR CO.
  14. Using the special tool, an axle bearing/seal elate, and a suitable cress, install the pinion bearing.
    15. NOTE: Use the thickness of the old drive pinion bearing preload shims as a starting point for setting pinion bearing preload.
  15. 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.
    1. Available
    2. Drive Pinion
    3. Bearing
    4. Preload
    5. Shims
      MATERIAL SPECIFICATION

      mm Inches
      0.36 0.014
      0.38 0.015
      0.41 0.016
      0.46 0.018
      0.51 0.020
      0.53 0.021
      0.56 0.022
      0.58 0.023
      0.76 0.030
  16. Assemble the drive pinion bearing preload shims onto the pinion and install the pinion into the differential housing.
  17. Install the outer pinion bearing.
  18. Using the special tool, install the pinion flange.
    Fig 14: Installing Pinion Flange Using Special Tool
    G02768970Courtesy of FORD MOTOR CO.
  19. Install the old washer and the lock nut.
    Fig 15: Installing Washer And The Lock Nut
    G02768971Courtesy of FORD MOTOR CO.
  20. Using a Nm (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 16: Rotating Pinion Using Torque Wrench
      G02768972Courtesy of FORD MOTOR CO.
  21. 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 17: Installing Method To Increase Or Decrease Backlash And Differential Bearing Preload
      G02768973Courtesy of FORD MOTOR CO.
  22. With the drive pinion at the correct preload as determined earlier in this procedure, remove and discard the lock nut and the washer.
    Fig 18: Removing Lock Nut And Washer Using Special Tool
    G02768974Courtesy of FORD MOTOR CO.
  23. Using the special tool, remove the pinion flange.
    Fig 19: Removing Pinion Flange Using Special Tool
    G02768975Courtesy of FORD MOTOR CO.
  24. Coat the pinion seal rubber lips with lubricant.
  25. Using the special tool, 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.
  26. Coat the inside of the pinion flange with a small amount of lubricant.
  27. Using the special tool, install the pinion flange.
    Fig 20: Installing Pinion Flange Using Special Tool
    G02768976Courtesy of FORD MOTOR CO.
    28. CAUTION: Always install a new washer and lock nut.
    Fig 21: Installing Washer And Lock Nut
    G02768977Courtesy of FORD MOTOR CO.
  28. Install the new washer and lock nut.
  29. Carry out the Ring Gear and Pinion Backlash  procedure.
  30. Assemble the differential bearing cups to the differential bearings.
    31. 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.
  31. 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.
        Fig 22: Spreading Differential Housing Using Special Tool
        G02768978Courtesy of FORD MOTOR CO.
    32. CAUTION: Match the mating letters as noted during disassembly.
    Fig 23: Aligning Mating Letters
    G02768979Courtesy of FORD MOTOR CO.
  32. Install the bearing caps, aligning the letters with those on the differential housing. Tighten the bolts to specification.
  33. 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 in) and cannot vary more than 0.05 mm (0.002 in) between points checked. A backlash variation of more than 0.05 mm (0.002 in) 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 24: Measuring Differential Ring Gear And Pinion Backlash Using Special Tool
      G02768980Courtesy of FORD MOTOR CO.
  34. Confirm the total preload.
    • Using a Nm (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.
    • 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 25: Measuring Torque Using Torque Wrench
      G02768981Courtesy of FORD MOTOR CO.
  35. Carry out the Tooth Contact Pattern Check to verify the final pinion position is correct. Refer to DRIVELINE SYSTEM-GENERAL INFORMATION .
  36. Install the axle shafts. Refer to REAR DRIVE AXLE/DIFFERENTIAL - DANA S135 .
    37. NOTE: Install the driveshaft to the index marks made during removal.
    Fig 26: Installing Retainers Bolts
    G02768982Courtesy of FORD MOTOR CO.
  37. Install new bolts and retainers.
    38. 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 remove and reapply new sealant.
    NOTE: The differential housing cover requires a silicone rubber sealer material, rather than a gasket.
    Fig 27: Applying Continuous Bead Of Sealant Of Specified Thickness To Differential Housing Cover
    G02768983Courtesy of FORD MOTOR CO.
  38. Apply a continuous bead of sealant of the specified thickness to the differential housing cover.
  39. Place two bolts into the differential housing cover at the 8 o'clock and 2 o'clock positions. Install the differential housing cover.
    • Use the two bolts to position the differential housing cover on the differential housing.
  40. Install the remaining bolts. Tighten the bolts alternately and evenly.
    • Allow 1-hour cure time before filling the axle with the correct amount of specified lubricant.
      Fig 28: Installing Differential Housing Cover Bolts (F350)
      G02768984Courtesy of FORD MOTOR CO.
      Fig 29: Installing Differential Housing Cover Bolts (F450, F550)
      G02768985Courtesy of FORD MOTOR CO.
    41. CAUTION: For Trac-Lok® axles, first fill the axle with 0.2365 liters (0.5 pints) of Additive Friction Modifier.
  41. Fill the axle with the specified type and amount of lubricant. Refer to SPECIFICATIONS .
  42. Lower the vehicle.
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