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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 8.8" Ring Gear >> In-Vehicle Repair >> Differential Bearings >> Installation

Differential Bearings: Installation

  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: Installing Differential Bearing On Differential Assembly
      G03237466Courtesy 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
      G03237467Courtesy of FORD MOTOR CO.
  3. Tighten the special tool to seat the pinion bearing cups in their bores.
    Fig 3: Tightening Special Tool
    G03237468Courtesy 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: Measuring Differential Pinion Bearing Cups Seating Position
    G03237469Courtesy 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.
  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 N.m (20 lb-in).
        Fig 5: Assembling And Position Drive Pinion Depth Gauge Set
        G03237470Courtesy of FORD MOTOR CO.
    6. NOTE: The gauge block must be offset to obtain an accurate reading.
    Fig 6: Rotating Gauge Block
    G03237471Courtesy 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 N.m (77 lb-ft).
        Fig 7: Installing Special Tool
        G03237472Courtesy 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.
  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 8: Identifying Drive Pinion Bearing Shim
      G03237473Courtesy of FORD MOTOR CO.
  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 And Drive Pinion Bearing Adjustment Shim
    G03237474Courtesy of FORD MOTOR CO.
  10. Install a new drive pinion collapsible spacer on the pinion shaft against the pinion shaft shoulder.
    Fig 10: Installing Drive Pinion Collapsible Spacer
    G03237475Courtesy of FORD MOTOR CO.
  11. Install the drive pinion assembly into the axle housing.
    Fig 11: Installing Drive Pinion Assembly Into Axle Housing
    G03237476Courtesy 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: Installing Drive Pinion Seal
    G03237477Courtesy of FORD MOTOR CO.
  14. Using the special tools, install the drive pinion flange.
    Fig 13: Installing Drive Pinion Flange
    G03237478Courtesy 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.
      Fig 14: Holding Pinion Flange For Tightening Pinion Nut
      G03237479Courtesy of FORD MOTOR CO.
  16. Place the differential carrier assembly with the new differential carrier bearing cups in the axle housing.
    Fig 15: Placing Differential Carrier Assembly With New Differential Carrier Bearing Cups In Axle Housing
    G03237480Courtesy of FORD MOTOR CO.
  17. Install a differential bearing shim on the LH side.
    Fig 16: Identifying Differential Bearing Shim Thickness
    G03237481Courtesy of FORD MOTOR CO.
    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 Bolts
    G03237482Courtesy 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 Larger Differential Bearing Shims On RH Side
    G03237483Courtesy of FORD MOTOR CO.
  20. Install the RH side differential bearing cap and tighten the differential bearing cap bolts.
    • Tighten to 105 N.m (77 lb-ft).
      Fig 19: Installing Differential Bearing Cap Bolts
      G03237484Courtesy of FORD MOTOR CO.
  21. Rotate the differential assembly to make sure it rotates freely.
    Fig 20: Rotating Differential Assembly
    G03237485Courtesy 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: Measuring Ring Gear Backlash
      G03237486Courtesy 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 ADJUSTING REFERENCE

    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 REFERENCE (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
  25. Rotate the differential assembly several times to make sure the differential bearings are seated.
    Fig 22: Rotating Differential Assembly
    G03237487Courtesy of FORD MOTOR CO.
  26. Using the special tools, recheck the ring gear backlash.
    Fig 23: Rechecking Ring Gear Backlash
    G03237488Courtesy of FORD MOTOR CO.
  27. Remove the differential bearing cap bolts and differential bearing caps.
  28. To establish differential bearing preload, increase both LH and RH differential bearing shim sizes as shown.
    Fig 24: Identifying LH And RH Differential Bearing Shim Sizes
    G03237489Courtesy of FORD MOTOR CO.
  29. Using the special tool, fully seat the differential bearing shims. Make sure the assembly rotates freely.
    Fig 25: Installing Differential Bearing Shims
    G03237490Courtesy of FORD MOTOR CO.
  30. Install the differential bearing caps and differential bearing cap bolts.
    • Tighten to 105 N.m (77 lb-ft).
      Fig 26: Installing Differential Bearing Cap Bolts
      G03237491Courtesy 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. Verify an acceptable pattern check.
  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: Aligning Index Marks On Pinion Flange
    G03237492Courtesy 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.
  36. Install the driveshaft flange bolts.
    • Tighten to 103 N.m (76 lb-ft).
      Fig 28: Installing Driveshaft Flange Bolts
      G03237493Courtesy of FORD MOTOR CO.
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