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Home >> Ford >> 2003 >> Cutaway 7.3 F >> Repair and Diagnosis >> External Pages >> Different car >> Section 2613 (Rear Drive Axle/Differential - Ford 10.50-Inch Ring Gear -- F250-F350 Super Duty) >> In-Vehicle Repair >> Differential Bearings >> Installation

Differential Bearings: Installation

WARNING: This page is about a different car, the 2011 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the inner and outer bearing cups.
    1. After placing the inner and outer bearing cups in their bores, place the Input Shaft Bearing Cup Installer on the inner pinion bearing cup.
    2. Place the Drive Pinion Bearing Installer on the outer pinion bearing cup.
    3. Install the Rear Axle Drawbar into the replacer tools.
    Fig 1: Installing Inner And Outer Bearing Cups Using Special Tool
    G07478597Courtesy of FORD MOTOR CO.
  2. Tighten the Rear Axle Drawbar to install the pinion bearing cups into their bores.
    Fig 2: Locating Pinion Bearing Cup
    G07478598Courtesy of FORD MOTOR CO.
  3. Make sure the cups are correctly seated in their bores.
    • If a feeler gauge of the specification shown in the illustration 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 3: Checking Drive Pinion Bearing Cups Position Using Special Tool
    G07478599Courtesy of FORD MOTOR CO.
  4. Assemble and position the Adapter, Drive Pinion Depth Gauge, Gauge Block Adapter, Gauge Tube and Pinion Depth Gauge.
    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.
    PARTS DESCRIPTION CHART

    Item Part Number Description
    1 4621 Pinion bearing (outer)
    2 205-160 Adapter (T80T-4020-F43)
    3 4630 Pinion bearing (inner)
    4 205-423 Drive Pinion Depth Gauge
    5 205-159 Gauge Block Adapter (2.1993-inch thick) (T80T-4020-F42)
    6 205-D038 Gauge Tube (4.126-inch OD) (D81T-4020-F51)
    7 205-937 Drive Pinion Depth Gauge/Aligner
    8 4010 Rear axle housing
    9 205-111 Handle (T76P-4020-A11)
    Fig 4: Identifying Special Tools
    G07478600Courtesy of FORD MOTOR CO.
  5. Tighten the Adapter to achieve the pinion bearing preload.
    NOTE: This step duplicates final pinion bearing preload.
    • Tighten to 2.2 Nm (20 lb-in).
    Fig 5: Tightening Adapter Using Special Tool
    G07478601Courtesy of FORD MOTOR CO.
  6. Rotate the Adapter several half-turns to make sure of correct seating of the pinion bearings, and position the Adapter.
    NOTE: The Adapter must be offset to obtain an accurate reading.
    Fig 6: Rotating Adapter Using Special Tool
    G07478602Courtesy of FORD MOTOR CO.
  7. Install the Gauge Tube.
    1. Position the Gauge Tube.
    2. Install the 2 differential bearing caps.
    3. Install the 4 differential bearing cap bolts.
      • Tighten to 118 Nm (87 lb-ft).
        Fig 7: Identifying Gauge Tube With Differential Bearing Caps And Bearing Cap Bolts
        G07478603Courtesy of FORD MOTOR CO.
  8. Use a drive pinion bearing adjustment shim as a gauge for shim selection.
    NOTE: Drive pinion bearing adjustment shims must be flat and clean.
    NOTE: A slight drag should be felt for correct shim selection. Do not attempt to force the pinion shim between the gauge block and the gauge tube.
    Fig 8: Locating Pinion Bearing Adjustment Shim
    G07478604Courtesy of FORD MOTOR CO.
  9. Place the selected shim on the pinion and press the bearing until it is firmly seated on the shaft using the Bearing/Oil Seal Plate and Drive Pinion Bearing Installer.
    NOTE: Check the splines on the pinion stem to be sure they are free of burrs. If burrs are evident, remove them by using a fine crocus cloth. Working in a rotational motion, wipe the pinion clean.
    NOTE: The same differential pinion bearing used in the previous procedure must be used in the final assembly of the axle.
    Fig 9: Pressing Pinion Bearing
    G07478605Courtesy of FORD MOTOR CO.
  10. Place a new collapsible spacer on the pinion shaft against the pinion stem shoulder.
    Fig 10: Locating Collapsible Spacer
    G07478606Courtesy of FORD MOTOR CO.
  11. Install the outer drive pinion bearing and drive pinion shaft oil slinger.
    Fig 11: Locating Outer Drive Pinion Bearing And Drive Pinion Shaft Oil Slinger
    G07478607Courtesy of FORD MOTOR CO.
  12. Lubricate the new drive pinion seal lips with grease.
  13. Using the Drive Pinion Oil Seal Installer, install the drive pinion oil seal.
    Fig 12: Installing Drive Pinion Oil Seal Using Drive Pinion Oil Seal Installer
    G07478608Courtesy of FORD MOTOR CO.
  14. Install the drive pinion in the drive pinion carrier bore from inside the rear axle housing.
    Fig 13: Locating Drive Pinion
    G07478609Courtesy of FORD MOTOR CO.
  15. Align the pinion and pinion flange alignment marks.
    Fig 14: View Of Pinion Flange Marking
    G07478610Courtesy of FORD MOTOR CO.
  16. With the drive pinion in place in the axle housing, install the pinion flange using the Drive Pinion Flange Holding Fixture and Drive Pinion Flange Installer.
    NOTE: The Drive Pinion Flange Installer must be used due to tight spline fit.
    Fig 15: Installing Pinion Flange Using Special Tools
    G07478611Courtesy of FORD MOTOR CO.
  17. Position the new pinion nut.
    Fig 16: Locating Pinion Nut
    G07478612Courtesy of FORD MOTOR CO.
  18. Using the Drive Pinion Flange Holding Fixture to hold the pinion flange, tighten the pinion nut to set the drive pinion bearing preload.
    NOTE: Do not loosen the pinion nut to reduce drive pinion bearing preload. Install a new drive pinion collapsible spacer and pinion nut if drive pinion bearing preload reduction is necessary. If a new collapsible spacer must be installed for pinion bearing preload reduction, install the nut supplied with the new spacer kit or damage to the component may occur.
    • Tighten the pinion nut, rotating the pinion occasionally to make sure the drive pinion bearings are seating correctly. Take frequent drive pinion bearing preload readings by rotating the drive pinion gear with a Nm (lb-in) torque wrench. The final readings must be 0.56 Nm (5 lb-in) more than the initial reading taken during removal. After the torque reading is correct, using a drift stake the pinion nut.
    • After the torque reading is correct, using a round tip centerpunch, stake the pinion nut.
    Fig 17: Tightening Pinion Nut Using Required Tool
    G07478613Courtesy of FORD MOTOR CO.
    Fig 18: Locating Pinion Nut Staking Positions
    G07478614Courtesy of FORD MOTOR CO.
  19. Position the differential case in the rear axle housing.
    • Install a shim on the left side as shown in the illustration.
    Fig 19: Identifying Shim Installation Position On Differential Case
    G07478615Courtesy of FORD MOTOR CO.
  20. Install the left bearing cap and loosely install the 2 bearing cap bolts.
    NOTE: The bearing caps must be installed in their original locations and positions.
    NOTE: Apply pressure toward the left side to make sure the left bearing is seated.
    Fig 20: Locating Left Bearing Cap Bolts
    G07478616Courtesy of FORD MOTOR CO.
  21. Install progressively larger shims on the right side until the largest shim selected can be assembled by hand.
    Fig 21: Locating Larger Shim On Differential Housing
    G07478617Courtesy of FORD MOTOR CO.
  22. Install the right side bearing cap with 2 bolts and tighten the 4 bolts.
    • Tighten to 118 Nm (87 lb-ft).
    Fig 22: Locating Differential Bearing Cap Bolts
    G07478618Courtesy of FORD MOTOR CO.
  23. Rotate the differential case to make sure it rotates freely.
    Fig 23: Locating Differential Case
    G07478619Courtesy of FORD MOTOR CO.
  24. Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, measure ring gear backlash.
    • If the backlash is within specification, go to Step 30.
    • If a zero backlash condition occurs, go to Step 25.
    • If the backlash is not within specification, go to Step 26.
    Fig 24: Measuring Ring Gear Backlash Using Special Tools
    G07478620Courtesy of FORD MOTOR CO.
  25. If a zero backlash condition occurs, add a 0.50 mm (0.020 in) shim to the RH side and subtract 0.50 mm (0.020 in) from the LH side to allow backlash indication. Repeat Step 24.
  26. To increase or decrease backlash, remove the 4 bearing cap bolts, the 2 bearing caps and install a thicker shim and a thinner shim as shown in illustration.
    NOTE: If backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness on the other differential bearing shim by the same amount.
    SHIMS SPECIFICATIONS

    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
    • If backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness on the other differential bearing shim by the same amount.
    Fig 25: Locating Differential Bearing Caps
    G07478621Courtesy of FORD MOTOR CO.
  27. Install the 2 bearing caps and 4 bearing cap bolts.
    • Tighten to 118 Nm (87 lb-ft).
    Fig 26: Locating Differential Bearing Cap Bolts
    G07478622Courtesy of FORD MOTOR CO.
  28. Rotate the differential several times to make sure the differential bearings are correctly seated.
    Fig 27: View Of Differential Case
    G07478623Courtesy of FORD MOTOR CO.
  29. Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, recheck the backlash.
    Fig 28: Checking Ring Gear Backlash Using Special Tools
    G07478624Courtesy of FORD MOTOR CO.
  30. Remove the 2 bearing caps and 4 bolts.
    • To establish differential bearing preload, increase both left and right shim sizes by the specification shown in the illustration.
    • Using the Differential Shim Installer, make sure the differential bearing shims are fully seated and the assembly turns freely.
    Fig 29: Installing Differential Shim Using Differential Shim Installer
    G07478625Courtesy of FORD MOTOR CO.
  31. Install the 2 bearing caps and 4 bearing cap bolts.
    • Tighten to 118 Nm (87 lb-ft).
    Fig 30: Locating Differential Bearing Cap Bolts
    G07478626Courtesy of FORD MOTOR CO.
  32. Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, verify the backlash.
    Fig 31: Checking Ring Gear Backlash Using Special Tools
    G07478627Courtesy of FORD MOTOR CO.
  33. Apply marking compound and rotate the differential assembly 5 complete revolutions.
  34. Verify an acceptable pattern check. For additional information, refer to DRIVELINE SYSTEM - GENERAL INFORMATION .
  35. Install the axle shafts. For additional information, refer to WHEEL HUBS AND BEARINGS - FULL FLOATING AXLE - FORD .
  36. Clean the gasket mating surface of the rear axle and the differential housing cover.
    NOTE: Make sure the machined surfaces on both the rear axle housing and the differential housing are clean and free of oil before applying the new silicone. The inside of the rear axle must be covered when cleaning the machined surface to prevent contamination.
  37. Apply a new, continuous bead of silicone to the differential housing cover as shown in illustration.
    Fig 32: Locating Silicone Applying Area Of Differential Housing Cover
    G07478628Courtesy of FORD MOTOR CO.
  38. Install the differential housing cover and the 12 differential housing cover bolts.
    NOTE: The differential housing cover must be installed within 15 minutes of application of the silicone, or new sealant must be applied. If possible, allow one hour before filling with lubricant to make sure the silicone has correctly cured.
    • For a stamped steel cover, tighten alternately and evenly to 45 Nm (33 lb-ft).
    • For a cast aluminum cover, tighten alternately and evenly to 32 Nm (24 lb-ft).
    Fig 33: Locating Differential Housing Cover Bolt
    G07478629Courtesy of FORD MOTOR CO.
  39. Remove the filler plug, fill the axle to the level shown with axle lubricant and install the filler plug.
    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.
    • Tighten to 30 Nm (22 lb-ft).
    Fig 34: Identifying Axle Lubricant Filling Level
    G07478630Courtesy of FORD MOTOR CO.
  40. Position the driveshaft and align the index mark on the pinion flange.
    Fig 35: Locating Pinion Flange Mark
    G07478631Courtesy of FORD MOTOR CO.
  41. Install the 4 new driveshaft flange bolts.
    NOTE: 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.
    • Tighten to 103 Nm (76 lb-ft).
    Fig 36: Locating Driveshaft Flange Bolts
    G07478632Courtesy of FORD MOTOR CO.
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