Disassembly And Assembly: Axle: Assembly

WARNING: This page is about a different car, the 2003 Ford Pickup, 2003 Ford F550 Super Duty, 2003 Ford F450 Super Duty, 2003 Ford Excursion, and 2003 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: To ease installation, coat the seal axle tube mating surfaces with lubricant.

Using the special tools, install the axle shaft oil seals.
- For model 50 axles, use special tools 205-428, 205-425 (LH), and 205-424 (RH) to install the axle shaft oil seals.
- For model 60 axles, use special tools 205-428, 205-427 (LH), and 205-426 (RH) to install the axle shaft oil seals.
Place the axle shaft oil seals onto the tool, and position the assembly into the differential housing. Lengthen the tool as necessary until both seals start evenly in the axle tubes. Continue to lengthen the tool until both step plates bottom out against the housing.

Fig 1: Placing Axle Shaft Oil Seals
Courtesy of FORD MOTOR CO.
Place the special tool on the differential case hubs, and position the assembly into the differential housing.
- For model 50 axles, use special tool 205-D046.
- For model 60 axles, use special tool 205-D047.
  
  Fig 2: Placing Special Tool On Differential Case Hubs
  Courtesy of FORD MOTOR CO.

NOTE: Use a Dial Indicator with a minimum travel capacity of 5.08 mm (0.200 inch).

NOTE: Repeat this step until there is a consistent reading.

Determine the total thickness of differential bearing shims to install on the differential case hubs, less the preload, which is calculated later in this procedure. Record this measurement as the total case end play.
1. Position the special tool.
2. Position the special tool.
  - Locate the tip of the tool on a flat surface of one of the ring gear bolt spot faces.
Force the ring gear as far as possible toward the special tool.
With the pressure still applied, zero the special tool.
Force the ring gear as far as it will go in the opposite direction.
Record the reading.

Fig 3: Placing Special Tool Differential Housing (1 Of 2)
Courtesy of FORD MOTOR CO.

Fig 4: Recording Reading While Forcing Ring Gear In Opposite Direction
Courtesy of FORD MOTOR CO.
Remove the differential case with the special tool from the differential housing.
- Do not remove the special tool from the differential case hubs.
  
  Fig 5: Removing Differential Case With Special Tool From Differential Housing
  Courtesy of FORD MOTOR CO.
Install the inner oil baffle and the inner and outer pinion bearing cups.
1. Position the oil baffle and the bearing cups in the differential housing.
2. Place the special tools on the inner and outer bearing cups.
  - For model 50 axles, place special tool 205-139 on the outer pinion bearing cup.
  - For model 50 axles, place special tool 205-140 on the inner pinion bearing cup.
  - For model 60 axles, place special tool 205-006 Bl on the outer pinion bearing cup.
  - For model 60 axles, place special tool 205-006 B2 on the inner pinion bearing cup.
Install and tighten special tool 205-098 to seat the cups.
- Remove the special tools after seating the cups.
  
  Fig 6: Installing Inner Oil Baffle And Inner And Outer Pinion Bearing Cups
  Courtesy of FORD MOTOR CO.
  
  Fig 7: Installing And Tighten Special Tool Seat Cups
  Courtesy of FORD MOTOR CO.

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 8: Checking Cups Have Seated Correctly In Bores

Courtesy of FORD MOTOR CO.

Check that the cups have seated correctly in their bores.

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.

Assemble and position the following in the differential housing.
1. Position the Adapter for 205-S156.
2. Position the Adapter for 205-S127.
3. Position the inner pinion bearing.
4. Position the Adapter for 205-S156 (model 50) or Adapter for 205-S127 (model 60).
5. Position the Adapter for 205-S156.
6. Position the outer pinion bearing.
7. Thread on the Adapter for 205-S127.
  
  Fig 9: Positioning Pinion Bearings (Model 50)
  Courtesy of FORD MOTOR CO.
  
  Fig 10: Positioning Pinion Bearings (Model 60)
  Courtesy of FORD MOTOR CO.

NOTE: This step simulates pinion bearing preload.

Fig 11: Identifying Special Tool Setup

Courtesy of FORD MOTOR CO.

Using a Nm (inch-pound) torque wrench, tighten the special tool to the specification.

NOTE: Offset the special tool to obtain an accurate reading.

Fig 12: Rotating Special Tool Several Half-Turns To Seat Pinion Bearings

Courtesy of FORD MOTOR CO.

Rotate the special tool several half-turns to seat the pinion bearings. Position the special tool as shown.
Install the special tool.
1. Position the special tool.
  - For model 50 axles, use tool 205-158.
  - For model 60 axles, use tool 205-D033.
2. Install the bearing caps.
3. Install the bolts.
  
  Fig 13: Installing Bearing Caps With Special Tool
  Courtesy of FORD MOTOR CO.

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 special tools. A slight drag indicates a correct selection.

Using a feeler gauge or flat, clean drive pinion position shims, measure the gap between the special tools. Record the measurement.
- Remove the special tools after making the correct shim selection.
  
  Fig 14: Checking Drag With Shim To Determine Correct Shim
  Courtesy of FORD MOTOR CO.

NOTE: The differential ring gear and pinion is only available in a matched set. Matching numbers etched on both the differential ring gear and pinion are for verification. If installing a new differential ring gear and pinion, verify these numbers match before proceeding with assembly. The end of the pinion with the etched figures is the "button" end.

NOTE: Use the gear contact pattern method to verify the final pinion position is valid. Refer to DRIVELINE SYSTEM - GENERAL INFORMATION .

Shim the pinion as follows:
- Etched on the button end of each pinion is a zero (0), or a plus (+) or minus (-) with a number. This number indicates the best running position for each particular differential ring gear. Shimming behind the inner pinion bearing (4630) controls this dimension.
  
  Fig 15: Identifying Ring And Pinion
  Courtesy of FORD MOTOR CO.
If reusing the old differential ring gear and pinion, proceed as follows:
- Measure and record the old drive pinion position shim thickness and select a new shim of the same dimension.
- To change the pinion adjustment, drive pinion position shims are available in the thickness shown in the following charts. Measure each shim separately with a micrometer.
Available Drive Pinion Position Shims (Model 50 Axles)

Fig 16: Available Drive Pinion Shims Specification Table (Model 50 Axles) (1 Of 2)
Courtesy of FORD MOTOR CO.

Fig 17: Available Drive Pinion Shims Specification Table (2 Of 2)
Courtesy of FORD MOTOR CO.

Available Drive Pinion Position Shims (Model 60 Axles)

Fig 18: Available Drive Pinion Shims (Model 60 Axles)
Courtesy of FORD MOTOR CO.
If installing a new differential ring gear and pinion, notice the (+) or (-) etching on both the old and new pinion, and adjust the new shim thickness to compensate for the difference of these two figures.
- For example, a pinion etched with m+8 (+3) requires 0.08 mm (0.003 inch) less shimming than a pinion etched "0". This means to increase the mounting distance by the amount etched in the pinion, subtract 0.08 mm (0.003 inch) from the drive pinion position shim selected for installation. A pinion etched m-8 (-3), requires 0.08 mm (0.003 inch) more shimming than a pinion etched "0". In this instance, add 0.08 mm (0.003 inch) to the drive pinion position shim selected for installation to decrease the pinion mounting distance by the amount etched in the pinion.
New Pinion Conversion Chart (Metric)

Fig 19: New Pinion Conversion Chart (Metric)
Courtesy of FORD MOTOR CO.

CAUTION: Follow the drive pinion bearing preload shim and drive pinion position shim assembly sequence as directed or unit failure can result.

Install the correct thickness drive pinion position shim on the pinion.
Using the special tools, install the differential pinion bearing.
- For model 50 axles, use an axle bearing/seal plate, special tool 205-004, and a suitable press to install the differential pinion bearing.
- For model 60 axles, use an axle bearing/seal plate, special tool 205-092, and a suitable press to install the differential pinion bearing.
  
  Fig 20: Installing Correct Thickness Drive Pinion Position Shim On Pinion
  Courtesy of FORD MOTOR CO.

NOTE: On model 50 axles, position the new collapsible spacer inside the differential housing before installing the pinion bearing and the oil slinger.

Fig 21: Installing New Collapsible Spacer

Courtesy of FORD MOTOR CO.

Install the new collapsible spacer (model 50 axles), the differential pinion bearing, and the oil slinger.
Using a suitable driver, install the pinion seal.
- Lightly coat the pinion seal lip with lubricant.
  
  Fig 22: Installing Pinion Seal
  Courtesy of FORD MOTOR CO.
On model 60 axles, install a new collapsible spacer.

Fig 23: Installing A Collapsible Spacer
Courtesy of FORD MOTOR CO.

CAUTION: Do not damage the pinion, the bearings, the seal, or the cup.

Fig 24: Inserting Pinion Into Differential Housing

Courtesy of FORD MOTOR CO.

Insert the pinion into the differential housing, and seat the inner bearing into the bearing cup.

CAUTION: Never use a metal hammer on the pinion flange or install the flange with power tools. If necessary, use a plastic hammer to tap on a tight fitting flange while holding the backside of the drive pinion.

NOTE: If reusing the original pinion and flange, align the index marks made during disassembly.

Fig 25: Identifying Flange Splines And Seal Mating Area With Lubricant

Courtesy of FORD MOTOR CO.

Lightly coat the flange splines and seal mating area with lubricant, then install the flange with a new washer and nut.

CAUTION: Never back off the pinion nut to reduce preload. If preload reduction is necessary, install a new collapsible spacer and pinion nut.

Fig 27: Positioning Differential Case With Special Tool Into Differential Housing

Courtesy of FORD MOTOR CO.

Tighten the nut.
- Use the special tool to prevent the flange from turning while tightening the nut. Remove the special tool when taking pinion bearing torque preload readings.
- Rotate the pinion occasionally to verify that the bearings are seating correctly.
- Take frequent pinion bearing torque preload readings.
  - If installing new differential pinion bearings, tighten the pinion nut to specifications. Refer to SPECIFICATIONS .
  - If installing the original pinion bearings, the final reading must be 0.56 Nm (5 lb-in) more than the initial reading taken during disassembly.
    
    Fig 26: Installing Original Pinion Bearings
    Courtesy of FORD MOTOR CO.
Position the differential case with the special tool into the differential housing.
- For model 50 axles, use special tool 205-D046.
- For model 60 axles, use special tool 205-D047.
  
  Fig 28: Inspecting Thickness Of Differential Bearing Shims
  Courtesy of FORD MOTOR CO.

NOTE: Repeat this step until there is a consistent reading.

Determine the total thickness of differential bearing shims to install under the differential bearing on the ring gear side of the differential case. Record this measurement, as the shim thickness required for the ring gear side of the differential case.
1. Position the special tool.
2. Position the special tool.
3. Force the ring gear into mesh with the pinion.
  - Rock the ring gear to allow the teeth of the gears to mesh.
4. With the pressure still applied, zero the special tool.
5. Force the ring gear away from the pinion.
6. Record the reading.
  
  Fig 29: Positioning Special Tool (1 Of 2)
  Courtesy of FORD MOTOR CO.
  
  Fig 30: Recording Reading While Pushing Ring Gear Away From Pinion
  Courtesy of FORD MOTOR CO.
Remove the differential case with the special tool from the differential housing.
- Remove the special tool from the differential case.
  
  Fig 31: Removing Special Tool From Differential Case
  Courtesy of FORD MOTOR CO.
Place the required thickness of differential bearing shims on the ring gear side of the differential case. Refer to the measurement recorded, as the shim thickness required for the ring gear side of the differential case. Differential bearing shims are available in the thickness shown in the following chart.
- For example, a reading of 1.14 mm (0.045 inch), requires that 1.14 mm (0.045 inch) shims be placed on the ring gear side of the differential case.
Available Differential Bearing Shims (Model 50 and Model 60 Axles)

Fig 32: Differential Bearing Shims Table (Model 50 And Model 60 Axles)
Courtesy of FORD MOTOR CO.
Using the special tool(s), install the differential bearing.
- For model 50 axles, use special tools 205-D055 and 205-142 to install the differential bearing.
- For model 60 axles, use special tool 205-D044 to install the differential bearing.
  
  Fig 33: Installing Differential Bearing
  Courtesy of FORD MOTOR CO.
Determine the total thickness of differential bearing shims to install under the differential bearing on the drive pinion side of the differential case.
- Subtract the measurement recorded, as the shim thickness required for the ring gear side of the differential case, from the total case end play measurement taken at the beginning of the assembly procedure. Then, add 0.38 mm (0.015 inch) to the total. This is the total amount of differential bearing shims to install under the differential bearing on the drive pinion side of the differential case.
Place the amount of differential bearing shims, as determined by the calculation made in the previous step, on the drive pinion side of the differential case.
Using the special tools, install the differential bearing.
1. Place the special tool under the bearing to protect it during the bearing installation.
  - For model 50 axles, use special tool 205-D016.
  - For model 60 axles, use special tool 205-D018.
2. Using the special tool(s), install the bearing.
  - For model 50 axles, use special tools 205-D055 and 205-142 to install the differential bearing.
  - For model 60 axles, use special tool 205-D044 to install the differential bearing.
    
    Fig 34: Installing Differential Bearing
    Courtesy of FORD MOTOR CO.
Position the differential bearing cups (4222) on the bearings.

Fig 35: Positioning Differential Bearing Cups On Bearings
Courtesy of FORD MOTOR CO.

CAUTION: Do not spread the differential housing more than specified.

CAUTION: Do not damage the ring gear and pinion.

Using the special tools, spread the differential housing.
- Use a soft face hammer to seat the differential into the differential housing.
  - Remove the special tools after seating the differential in the differential housing.
    
    Fig 36: Identifying Special Tool To Spread Differential
    Courtesy of FORD MOTOR CO.

CAUTION: Match the positioning of the mating letters on the bearing caps and the differential housing.

Fig 37: Installing Bearing Caps

Courtesy of FORD MOTOR CO.

Install the bearing caps.
Using the special tools, measure backlash at three equally spaced points.
- The backlash must be within the specifications, and cannot vary more than 0.05 mm (0.002 in) between points checked. A backlash variation or more than 0.05 mm (0.002 in) indicates gear/case runout.
  - Make the necessary corrections by moving shims from one side of the differential case to the other, until the correct backlash adjustment is achieved.
    - Correct for high backlash by moving the ring gear toward the pinion.
    - Correct for low backlash by moving the ring gear away from the pinion.
      
      Fig 38: Measuring Backlash At Three Equally Spaced Points
      Courtesy of FORD MOTOR CO.
Check the gear tooth contact pattern. Refer to DRIVELINE SYSTEM - GENERAL INFORMATION .

Fig 39: Checking Gear Tooth Contact Pattern
Courtesy of FORD MOTOR CO.

CAUTION: Clean the differential housing cover mounting surfaces with a suitable solvent, to remove all traces of oil film or foreign material.

NOTE: The differential housing cover requires the use of silicone sealant material rather than a gasket.

NOTE: Install the differential housing cover within 15 minutes of applying the silicone material.

Fig 40: Applying Specified Bead Of Silicone Rubber Sealer

Courtesy of FORD MOTOR CO.

Apply the specified bead of silicone rubber sealer as shown.

CAUTION: Allow one hour curing time before filling the axle with lubricant.

NOTE: Place two cover bolts into the differential housing cover at the 2 o'clock and 8 o'clock positions. This will help to position the differential housing cover onto the differential housing.

Fig 41: Installing Differential Cover

Courtesy of FORD MOTOR CO.

Install the differential housing cover.
Install the axle assembly. Refer to Axle Assembly .
Install the axle shaft assemblies and the front wheel hubs. Refer to FRONT - 4WD LEAF SPRING - EXCURSION, F250-F550 SUPER DUTY PICKUPS .
Fill the axle with the specified type and quantity of lubricant.