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Home >> Ford >> 2004 >> Mustang Mach 1, Standard >> Repair and Diagnosis (Single Page) >> Drivelines & Axles >> Differentials & Drive Axles >> Rear Drive Axle/Differential - Ford 7.5" Ring Gear >> In-Vehicle Repair >> Differential Ring and Pinion >> Installation

Differential Ring and Pinion: Installation

  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: Installing Special Tool
      G03237187Courtesy of FORD MOTOR CO.
  2. Tighten the special tool to seat the drive pinion bearing cups into their bores.
    Fig 2: Tightening Special Tool
    G03237188Courtesy 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: Inserting Feeler Gauge
    G03237189Courtesy of FORD MOTOR CO.
    Fig 4: Installing Special Tool
    G03237190Courtesy 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 5: Assembling And Positioning Special Tools
    G03237191Courtesy 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 N.m (20 lb-in).
      Fig 6: Tightening Special Tool
      G03237192Courtesy of FORD MOTOR CO.
    6. NOTE: The special tool must be offset to obtain an accurate reading.
    Fig 7: Rotating Special Tool
    G03237193Courtesy 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 N.m (77 lb-ft).
        Fig 8: Installing Special Tool
        G03237194Courtesy 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 9: Locating Shim
      G03237195Courtesy of FORD MOTOR CO.
  9. Using the special tool, press the inner drive pinion bearing and drive pinion bearing adjustment shim until it is firmly seated on the pinion shaft.
    Fig 10: Pressing Inner Drive Pinion Bearing
    G03237196Courtesy of FORD MOTOR CO.
  10. Install a new drive pinion collapsible spacer on the pinion shaft against the pinion shaft shoulder.
    Fig 11: Installing Drive Pinion Collapsible Spacer
    G03237197Courtesy of FORD MOTOR CO.
  11. Install the outer drive pinion bearing and the drive pinion shaft oil slinger.
    Fig 12: Installing Outer Drive Pinion Bearing
    G03237198Courtesy of FORD MOTOR CO.
  12. Using the special tools, install the drive pinion seal.
    Fig 13: Installing Drive Pinion Seal
    G03237199Courtesy of FORD MOTOR CO.
  13. Install the drive pinion assembly into the axle housing.
    Fig 14: Installing Drive Pinion Assembly
    G03237200Courtesy of FORD MOTOR CO.
  14. Using the special tools, install the drive pinion flange.
    Fig 15: Installing Drive Pinion Flange
    G03237201Courtesy 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 N.m (inch-pound) 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 N.m (inch-pound) 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.
      • Tighten to a rotational torque of 1.8-3.3 N.m (16-29 lb-in).
        Fig 16: Installing Special Tool
        G03237202Courtesy of FORD MOTOR CO.
  16. Using the special tool, install the new differential bearings.
    Fig 17: Installing Differential Bearings
    G03237203Courtesy of FORD MOTOR CO.
  17. Press the differential ring gear on the differential assembly.
    Fig 18: Pressing Differential Ring Gear
    G03237204Courtesy of FORD MOTOR CO.
    18. NOTE: Apply stud and bearing mount to the differential ring gear bolts.
  18. Install the differential ring gear bolts.
    • Tighten to 105 N.m (77 lb-ft).
      Fig 19: Installing Differential Ring Gear Bolts
      G03237205Courtesy of FORD MOTOR CO.
  19. Position the differential carrier assembly and the new differential bearing cups in the differential housing.
    Fig 20: Positioning Differential Carrier Assembly
    G03237206Courtesy of FORD MOTOR CO.
  20. Install a differential bearing shim of the shown dimension on the LH side.
    Fig 21: Installing Differential Bearing Shim
    G03237207Courtesy of FORD MOTOR CO.
    21. CAUTION: Always install the bearing caps in their original locations and positions.
    NOTE: Apply pressure toward the left side to make sure the LH differential bearing cup seats correctly.
    Fig 22: Installing LH Bearing Cap Bolts
    G03237208Courtesy of FORD MOTOR CO.
  21. Install the LH bearing cap and loosely install the bolts.
  22. Install progressively larger differential bearing shims on the RH side until the largest shim is installed by hand.
    Fig 23: Installing Progressively Larger Differential Bearing Shims
    G03237209Courtesy of FORD MOTOR CO.
  23. Install the right side bearing cap and bolts. Tighten the LH and RH bearing cap bolts.
    • Tighten to 105 N.m (77 lb-ft).
  24. Rotate the differential carrier several times to verify the differential bearings have seated correctly.
    Fig 24: Rotating Differential Carrier
    G03237210Courtesy of FORD MOTOR CO.
  25. Install the special tools and measure the ring gear backlash.
    • If the backlash is within specification, proceed to step 28.
    • If a zero backlash condition occurs, proceed to step 26.
    • If the backlash is not within specification, proceed to step 27.
      Fig 25: Installing Special Tools
      G03237211Courtesy of FORD MOTOR CO.
  26. 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  25.
  27. 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 specification, proceed to step  28.
    BACKLASH CHANGE/SHIM SPECIFICATIONS

    Backlash Change Required Thickness Change Required
    mm in mm in
    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 in
    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
  28. Remove the bearing cap bolts and bearing caps.
  29. To establish differential bearing preload, increase both LH and RH differential bearing shim size by the thickness shown.
    Fig 26: Removing Bearing Cap And Bolts
    G03237212Courtesy of FORD MOTOR CO.
  30. Using the special tool, fully seat the differential bearing shims. Make sure the assembly rotates freely.
    Fig 27: Installing Special Tool
    G03237213Courtesy of FORD MOTOR CO.
  31. Install the bearing caps and bolts.
    • Tighten to 105 N.m (77 lb-ft).
      Fig 28: Installing Bearing Caps And Bolts
      G03237214Courtesy of FORD MOTOR CO.
  32. Using the special tools, recheck the ring gear backlash.
  33. Apply marking compound and rotate the differential assembly 5 complete revolutions.
  34. Verify an acceptable pattern check.
  35. Install the axle shafts. For additional information, refer to AXLE SHAFT .
  36. Position the driveshaft and align the index marks on the pinion flange.
    Fig 29: Aligning Index Marks
    G03237215Courtesy of FORD MOTOR CO.
    37. 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.
  37. Install the driveshaft flange bolts.
    • Tighten to 103 N.m (76 lb-ft).
      Fig 30: Installing Driveshaft Flange Bolts
      G03237216Courtesy of FORD MOTOR CO.
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