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Differential Bearings: Installation

WARNING: This page is about a different car, the 2009 Mercury Grand Marquis and 2009 Ford Crown Victoria. 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 special tool, press the differential bearings on the differential assembly.
    2. Fig 1: Installing Differential Bearings
    G03878661Courtesy 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.
    3. Fig 2: Identifying Special Tool Components
    G03878597Courtesy of FORD MOTOR CO.
  3. Tighten the special tool to seat the pinion bearing cups in their bores.
    4. Fig 3: Identifying Special Tool To Seat Pinion Bearing Cups
    G03878598Courtesy of FORD MOTOR CO.
    NOTE: If a feeler gauge of the specification shown in 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.
  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 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 Nm (20 lb-in).
    6. Fig 5: Identifying Drive Pinion Depth Gauge Set
    GF0003082Courtesy of FORD MOTOR CO.
    NOTE: The gauge block must be offset to obtain an accurate reading.
  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. Fig 6: Rotating Gauge Block For Correct Seating Of Drive Pinion Bearings
    G03878602Courtesy of FORD MOTOR CO.
  7. Install the special tool.
    1. Position the gauge tube and the paper shipping tabs.
    2. Install the 2 differential bearing caps.
    3. Install the 4 differential bearing cap bolts.
      • Tighten to 114 Nm (84 lb-ft).
    8. Fig 7: 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.
  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.
    9. Fig 8: Identifying Drive Pinion Bearing Adjustment Shim
    GF0000868Courtesy 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.
    10. Fig 9: Locating Inner Drive Pinion Bearing
    G03878605Courtesy of FORD MOTOR CO.
  10. Install a new drive pinion collapsible spacer on the pinion shaft against the pinion shaft shoulder.
    11. Fig 10: Identifying Drive Pinion Collapsible Spacer
    GF0000836Courtesy of FORD MOTOR CO.
  11. Install the drive pinion assembly into the axle housing.
    12. Fig 11: Locating Drive Pinion Gear
    GF0000840Courtesy 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.
    14. Fig 12: Using Special Tool (205-208) To Install Drive Pinion Seal
    G03878608Courtesy of FORD MOTOR CO.
  14. Using the special tools, install the drive pinion flange.
    15. Fig 13: Using Special Tools To Hold Drive Pinion Flange
    G03878609Courtesy of FORD MOTOR CO.
    CAUTION: Do not, under any circumstance, loosen the drive pinion nut to reduce pinion bearing preload or component damage may occur. If it is necessary to reduce the preload, install a new drive pinion collapsible spacer and drive pinion nut.
    NOTE: Remove the special tool while taking rotational pinion bearing preload checks with the Nm (lb-in) 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 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.
    16. Fig 14: Pinion Flange Nut
    GF0013948Courtesy of FORD MOTOR CO.
  16. Place the differential carrier assembly with the new differential carrier bearing cups in the axle housing.
    17. Fig 15: Positioning Differential Assembly In Axle Housing
    GF0000841Courtesy of FORD MOTOR CO.
  17. Install a differential bearing shim on the LH side.
    18. Fig 16: Locating Differential Bearing Shim
    G03878614Courtesy of FORD MOTOR CO.
    NOTE: Apply pressure toward the LH side to make sure the left differential bearing cup is seated.
  18. Install the LH differential bearing cap and loosely install the differential bearing cap bolts.
    19. Fig 17: Identifying LH Differential Bearing Cap And Bolts
    GF0000842Courtesy of FORD MOTOR CO.
  19. Install progressively larger differential bearing shims on the RH side until the largest differential bearing shim selected can be inserted by hand.
    20. Fig 18: Differential Bearing Shim
    GF0000869Courtesy of FORD MOTOR CO.
  20. Install the RH side differential bearing cap and tighten the 2 differential bearing cap bolts.
    • Tighten to 114 Nm (84 lb-ft).
    21. Fig 19: Identifying Differential Bearing Cap And Differential Bearing Cap Bolts
    G03878679Courtesy of FORD MOTOR CO.
  21. Rotate the differential assembly to make sure it rotates freely.
  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.
    23. Fig 20: Measuring Ring Gear Backlash
    G03878618Courtesy 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 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
  25. Rotate the differential assembly several times to make sure the differential bearings are seated.
  26. Using the special tools, recheck the ring gear backlash.
    27. Fig 21: Measuring Ring Gear Backlash
    G03878618Courtesy of FORD MOTOR CO.
  27. Remove the 4 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 in illustration.
    29. Fig 22: Identifying Differential Bearing Shim For Preload (With Specifications)
    G03878619Courtesy of FORD MOTOR CO.
  29. Using the special tool, fully seat the differential bearing shims. Make sure the assembly rotates freely.
    30. Fig 23: Seating Differential Bearing Shims Using Special Tool
    G03878620Courtesy of FORD MOTOR CO.
  30. Install the 2 differential bearing caps and 4 differential bearing cap bolts.
    • Tighten to 114 Nm (84 lb-ft).
    31. Fig 24: Identifying Differential Bearing Cap And Differential Bearing Cap Bolts
    G03878679Courtesy 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. Install the driveshaft. For additional information, refer to DRIVESHAFT article.
    36. WARNING: If the vehicle is equipped with a fire suppression system, repower the system. For important safety warnings and procedures, refer to FIRE SUPPRESSION SYSTEM article. Failure to follow these instructions may result in serious personal injury.
  36. Repower the fire suppression system.
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