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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 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: Positioning Special Tool And Inner And Outer Drive Pinion Bearing Cups
      G03237420Courtesy of FORD MOTOR CO.
  2. Tighten the special tool to seat the drive pinion bearing cups into their bores.
    Fig 2: Seating Drive Pinion Bearing Cups Into Bores
    G03237421Courtesy 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: Identifying Feeler Gauge Specification
    G03237422Courtesy 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 4: Assembling And Positioning Special Tools
    G03237423Courtesy 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 5: Tightening Special Tool
      G03237424Courtesy of FORD MOTOR CO.
    6. NOTE: The special tool must be offset to obtain an accurate reading.
    Fig 6: Rotating Special Tool
    G03237425Courtesy 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 7: Tightening Differential Bearing Cap Bolts
        G03237426Courtesy 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 8: Identifying Bearing Adjustment Shim
      G03237427Courtesy of FORD MOTOR CO.
  9. Using the special tool and a shop press, drive the inner drive pinion bearing and the selected drive pinion bearing adjustment shim until they are firmly seated on the pinion shaft.
    Fig 9: Installing Inner Drive Pinion Bearing
    G03237428Courtesy 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
    G03237429Courtesy of FORD MOTOR CO.
  11. Install the drive pinion assembly into the axle housing.
    Fig 11: Installing Drive Pinion Assembly Into Axle Housing
    G03237430Courtesy of FORD MOTOR CO.
  12. Install the outer drive pinion bearing and the drive pinion shaft oil slinger.
  13. Using the special tools, install the drive pinion seal.
    Fig 12: Installing Drive Pinion Seal
    G03237431Courtesy of FORD MOTOR CO.
  14. Using the special tools, install the drive pinion flange.
    Fig 13: Installing Drive Pinion Flange
    G03237432Courtesy 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: Tightening Pinion Nut
      G03237433Courtesy of FORD MOTOR CO.
  16. Using the special tool, install the new differential bearings.
    Fig 15: Installing New Differential Bearings
    G03237434Courtesy of FORD MOTOR CO.
    17. NOTE: Apply stud and bearing mount to the differential ring gear bolts.
  17. Install the differential ring gear bolts.
    • Tighten to 105 N.m (77 lb-ft).
      Fig 16: Installing Differential Ring Gear Bolts
      G03237435Courtesy of FORD MOTOR CO.
  18. Position the differential carrier assembly and the new differential bearing cups in the differential housing.
    Fig 17: Positioning Differential Carrier Assembly And Bearing Cups
    G03237436Courtesy of FORD MOTOR CO.
  19. Install a differential bearing shim of the shown dimension on the left side.
    Fig 18: Identifying Bearing Shim Dimension
    G03237437Courtesy of FORD MOTOR CO.
    20. CAUTION: Always install the bearing caps in their original locations and positions.
    NOTE: Apply pressure toward the LH side to make sure the left differential bearing cup seats correctly.
    Fig 19: Installing LH Bearing Cap And Bolts
    G03237438Courtesy of FORD MOTOR CO.
  20. Install the LH bearing cap and loosely install the bolts.
  21. Install progressively larger differential bearing shims on the RH side until the largest shim is installed by hand.
    Fig 20: Installing Larger Differential Bearing Shims On RH Side
    G03237439Courtesy of FORD MOTOR CO.
  22. Install the right side bearing cap and bolts. Tighten the LH and RH bearing cap bolts.
    • Tighten to 105 N.m (77 lb-ft).
  23. Rotate the differential carrier several times to verify the differential bearings have seated correctly.
    Fig 21: Rotating Differential Carrier
    G03237440Courtesy of FORD MOTOR CO.
  24. Install the special tools and measure the ring gear backlash.
    • If the backlash is within specification, proceed to step  27.
    • If a zero backlash condition occurs, proceed to step  25.
    • If the backlash is not within specification, proceed to step  26.
      Fig 22: Measuring Ring Gear Backlash
      G03237441Courtesy of FORD MOTOR CO.
  25. If a zero backlash condition occurs, add 0.50 mm (0.020 in) to the RH hand side shim and subtract 0.50 mm (0.020 in) from the LH side shim to allow a backlash indication. Go back to step  24.
  26. 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  27.
    DIFFERENTIAL BEARING SHIM SPECIFICATION

    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
  27. Remove the bearing cap bolts and bearing caps.
  28. To establish differential bearing preload, increase both LH and RH differential bearing shim size by the thickness shown.
    Fig 23: Identifying Differential Bearing Shim Thickness
    G03237442Courtesy of FORD MOTOR CO.
  29. Using the special tool, fully seat the differential bearing shims. Make sure the assembly rotates freely.
    Fig 24: Installing Bearing Shims
    G03237443Courtesy of FORD MOTOR CO.
  30. Install the bearing caps and bolts.
    • Tighten to 105 N.m (77 lb-ft).
      Fig 25: Installing Bearing Caps And Bolts
      G03237444Courtesy of FORD MOTOR CO.
  31. Using the special tools, recheck the ring gear 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. CAUTION: Make sure the machined surfaces on both the axle housing and the differential housing cover are clean and free of oil before applying the new silicone sealant. The inside of the axle must be covered when cleaning the machined surface to prevent contamination.
  35. Clean the gasket mating surface of the axle and the differential housing cover.
  36. Apply a new, continuous bead of sealant to the differential housing cover.
    Fig 26: Applying Sealant To Differential Housing Cover
    G03237445Courtesy of FORD MOTOR CO.
    37. 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 1 hour before filling with lubricant to ensure the silicone sealant has properly cured.
  37. Install the differential housing cover and the differential housing cover bolts.
    • Tighten to 45 N.m (33 lb-ft).
      Fig 27: Installing Differential Housing Cover Bolts
      G03237446Courtesy of FORD MOTOR CO.
    38. CAUTION: For Traction-Lok® axles, first fill the axle with 118 ml (4 ounces) of friction modifier.
    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.
  38. Fill the axle to the level shown with axle lubricant and install the filler plug.
    • Tighten to 30 N.m (22 lb-ft).
      Fig 28: Identifying Lubricant Filling Level
      G03237447Courtesy of FORD MOTOR CO.
  39. Position the driveshaft and align the index marks on the pinion flange.
    Fig 29: Identifying Index Marks On Pinion Flange
    G03237448Courtesy of FORD MOTOR CO.
    40. 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.
  40. Install the driveshaft flange bolts.
    • Tighten to 103 N.m (76 lb-ft).
      Fig 30: Installing Driveshaft Flange Bolts
      G03237449Courtesy of FORD MOTOR CO.
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