LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2009 >> Flex Limited, FWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1426 (Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear) >> In-Vehicle Servicing >> Differential Bearings >> Installation

Differential Bearings: Installation

WARNING: This page is about a different car, the 2009 Ford Mustang. However, it is still accessible from the selected car via links, so may be relevant.
  1. Press the left and right differential bearing on the differential assembly.
    1. Position the differential bearings.
    2. Using the Differential Side Bearing Installer, press the differential bearings on the differential assembly.
    2. Fig 1: Installing Differential Bearings
    G03878661Courtesy of FORD MOTOR CO.
  2. Position the Drive Pinion Bearing Cup Installer 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 Drive Pinion Bearing Cup Installer (inner) on the inner drive pinion bearing cup.
    2. Place the Drive Pinion Bearing Cup Installer (outer) on the outer drive pinion bearing cup.
    3. Install the Drive Pinion Bearing Cup Installer.
    3. Fig 2: Identifying Special Tool (205-024) Components
    G03878597Courtesy of FORD MOTOR CO.
  3. Tighten the Drive Pinion Bearing Cup Installer to seat the drive pinion bearing cups into their bores.
    4. Fig 3: Identifying Special Tool (205-024) To Seat Pinion Bearing Cups
    G03878598Courtesy of FORD MOTOR CO.
    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.
  4. Make sure the differential pinion bearing cups are correctly seated.
    5. Fig 4: Checking Clearance Between Cup And Bore
    G03878664Courtesy of FORD MOTOR CO.
    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 Adapters for 205-S127.
    Item Part Number Description
    1 205-105 Adapter for 205-S127 (1.612 inch OD) (T76P-4020-A3)
    2 205-111 Adapter for 205-S127 (T76P-4020-A11)
    3 4621 Drive pinion bearing (outer)
    4 205-109 Adapter for 205-S127 (T76P-4020-A9)
    5 4630 Drive pinion bearing (inner)
    6 205-129 Adapter for 105-S127 (1.1884 inch thick) (T79P-4020-A18)
    7 205-110 Adapter for 205-S127 (1.7 inch thick) (T76P-4020-A10)
    6. Fig 5: Identifying Drive Pinion Depth Gauge Set
    GF0003082Courtesy of FORD MOTOR CO.
    NOTE: This step duplicates final drive pinion bearing preload.
  6. Tighten the Adapter.
    • Tighten to 2.2 Nm (20 lb-in).
    7. Fig 6: Checking Differential Pinion Bearing Preload
    G03878601Courtesy of FORD MOTOR CO.
    NOTE: The Adapter must be offset to obtain an accurate reading.
  7. Rotate the Adapter several half-turns to make sure of correct seating of the drive pinion bearings and position the Adapter.
    8. Fig 7: Rotating Gauge Block For Correct Seating Of Drive Pinion Bearings
    G03878602Courtesy of FORD MOTOR CO.
  8. Install the Adapter.
    1. Position the Adapter.
    2. Install the 2 differential bearing caps.
    3. Install the 4 differential bearing cap bolts.
      • Tighten to 105 Nm (77 lb-ft).
    9. Fig 8: Identifying Special Tool (205-130)
    G03878603Courtesy of FORD MOTOR CO.
    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.
  9. 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 Adapters.
    10. Fig 9: Identifying Drive Pinion Bearing Adjustment Shim
    GF0000868Courtesy of FORD MOTOR CO.
  10. Using the Drive Pinion Bearing Cone Installer and Bearing Oil Seal Plate with 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.
    11. Fig 10: Locating Inner Drive Pinion Bearing
    G03878605Courtesy of FORD MOTOR CO.
  11. Install a new drive pinion collapsible spacer on the pinion shaft against the pinion shaft shoulder.
    12. Fig 11: Identifying Drive Pinion Collapsible Spacer
    GF0000836Courtesy of FORD MOTOR CO.
  12. Install the drive pinion assembly into the axle housing.
    13. Fig 12: Locating Drive Pinion Gear
    GF0000840Courtesy of FORD MOTOR CO.
  13. Install the outer drive pinion bearing and the drive pinion shaft oil slinger.
  14. Using the Drive Pinion Oil Seal Installer, install the drive pinion seal.
    15. Fig 13: Using Special Tool (205-208) To Install Drive Pinion Seal
    G03878608Courtesy of FORD MOTOR CO.
  15. Using the Drive Pinion Flange Holding Fixture and Drive Pinion Flange Installer, install the drive pinion flange.
    16. Fig 14: Installing Drive Pinion Flange Using Special Tools 205-126 & 205-002
    GF0015355Courtesy of FORD MOTOR CO.
    NOTE: 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.
    NOTE: Remove the Drive Pinion Flange Holding Fixture while taking rotational pinion bearing preload checks with the Nm (lb-in) torque wrench.
  16. Use the Drive Pinion Flange Holding Fixture 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 Nm (lb-in) 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.
    17. Fig 15: Using Special Tool 205-126 To Hold Pinion Flange While Removing/Installing Drive Pinion Nut
    GF0015351Courtesy of FORD MOTOR CO.
  17. Place the differential carrier assembly with the new differential carrier bearing cups in the axle housing.
    18. Fig 16: Identifying Differential Carrier Assembly
    GF0015356Courtesy of FORD MOTOR CO.
  18. Install a differential bearing shim on the LH side.
    19. Fig 17: Identifying Differential Bearing Shim
    GF0015357Courtesy of FORD MOTOR CO.
    NOTE: Apply pressure toward the LH side to make sure the left differential bearing cup is seated.
  19. Install the LH differential bearing cap and loosely install the 2 differential bearing cap bolts.
    20. Fig 18: Locating LH Bearing Cap & Bolts
    GF0015358Courtesy of FORD MOTOR CO.
  20. Install progressively larger differential bearing shims on the RH side until the largest differential bearing shim selected can be inserted by hand.
    21. Fig 19: Differential Bearing Shim
    GF0000869Courtesy of FORD MOTOR CO.
  21. Install the RH side differential bearing cap and tighten the 4 differential bearing cap bolts.
    • Tighten to 105 Nm (77 lb-ft).
    22. Fig 20: Locating Bearing Caps & Bolts
    GF0015359Courtesy of FORD MOTOR CO.
  22. Rotate the differential assembly to make sure it rotates freely.
    23. Fig 21: Rotating Differential Assembly
    GF0000870Courtesy of FORD MOTOR CO.
  23. Install the Dial Indicator With Holding Fixture and measure the ring gear backlash.
    • If the backlash is within specification, proceed to Step 26.
    • If a zero backlash condition occurs, proceed to Step 24.
    • If the backlash is not within specification, proceed to Step 25.
    24. Fig 22: Measuring Ring Gear Backlash
    G03878618Courtesy of FORD MOTOR CO.
  24. 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.
  25. 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 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
    DIFFERENTIAL SHIM SIZE CHART 4067

    Stripes and Color Code Dimension A
    mm Inch
    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
  26. Rotate the differential assembly several times to make sure the differential bearings are seated.
    27. Fig 23: Rotating Differential Assembly
    GF0000870Courtesy of FORD MOTOR CO.
  27. Using the Dial Indicator With Holding Fixture, recheck the ring gear backlash.
    28. Fig 24: Measuring Ring Gear Backlash
    G03878618Courtesy of FORD MOTOR CO.
  28. Remove the differential bearing cap bolts and differential bearing caps.
  29. To establish differential bearing preload, increase both LH and RH differential bearing shim sizes as shown.
    30. Fig 25: Identifying Differential Bearing Shim For Preload With Specifications
    G03878619Courtesy of FORD MOTOR CO.
  30. Using the Differential Shim Installer, fully seat the differential bearing shims. Make sure the assembly rotates freely.
    31. Fig 26: Seating Differential Bearing Shims Using Special Tool (205-220)
    G03878620Courtesy of FORD MOTOR CO.
  31. Install the 2 differential bearing caps and 4 differential bearing cap bolts.
    • Tighten to 105 Nm (77 lb-ft).
    32. Fig 27: Locating Bearing Caps & Bolts
    GF0015359Courtesy of FORD MOTOR CO.
  32. Using the Dial Indicator with Holding Fixture, recheck the ring gear backlash.
    33. Fig 28: Measuring Ring Gear Backlash
    G03878618Courtesy of FORD MOTOR CO.
  33. Apply marking compound and rotate the differential assembly 5 complete revolutions.
  34. Check and verify an acceptable pattern.
  35. Install the axle shafts. For additional information, refer to Axle Shaft .
  36. Install the driveshaft. For additional information, refer to DRIVESHAFT .
scientia non olet · About LEMON Manuals