LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2009 >> Flex Limited, FWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 2056 (Engine Mechanical - 2.5L (Hybrid)) >> General Procedures >> Balance Shaft Backlash

Balance Shaft Backlash

WARNING: This page is about a different car, the 2011 Mercury Milan, 2011 Lincoln MKZ, and 2011 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL(S)

G07781877
 Dial Indicator Gauge with Holding Fixture
100-002 (TOOL-4201-C)
G07781878
 Timing Peg, Crankshaft TDC
303-507
  1. Install the Crankshaft TDC Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at Top Dead Center (TDC).
    Fig 1: Identifying Crankshaft TDC Timing Peg
    G07781879Courtesy of FORD MOTOR CO.
  2. Mark the balancer unit and shafts on the top for reference that the balancer unit is at TDC.
    Fig 2: Locating Balancer Unit And Shafts Reference Mark
    G07781880Courtesy of FORD MOTOR CO.
    3. NOTE: Due to the precision interior construction of the balancer unit, it should not be disassembled.
    Fig 3: Locating Balancer Unit Mounting Bolts
    G07781881Courtesy of FORD MOTOR CO.
  3. Remove the 4 bolts and the balancer unit.
  4. Remove the adjustment shims from the seat faces of the balancer unit.
    5. NOTE: Visually inspect the balancer unit gear for damage and verify that the shaft turns smoothly. If there is any damage or malfunction, replace the balancer unit.
  5. Install the master adjustment shims (No. 50) on the seat faces of the balancer unit.
  6. With the balancer unit shaft marks at the TDC position, slowly install the balancer unit to the cylinder block to avoid interference between the crankshaft drive gear and the balancer unit driven gear.
    Fig 4: Locating Balancer Unit And Shafts Reference Mark
    G07781882Courtesy of FORD MOTOR CO.
  7. Install the balancer unit bolts.
    • Tighten in the sequence shown in illustration in 2 stages.
    • Stage 1: Tighten to 25 Nm (18 lb-ft).
    • Stage 2: Tighten to 50 Nm (37 lb-ft).
    Fig 5: Identifying Balancer Unit Bolts Tightening Sequence
    G07781883Courtesy of FORD MOTOR CO.
  8. Remove the Crankshaft TDC Timing Peg.
    • Rotate the crankshaft to confirm that there are no meshing problems between the balancer unit gear and the crankshaft gear.
    Fig 6: Identifying Crankshaft TDC Timing Peg
    G07781884Courtesy of FORD MOTOR CO.
  9. Install the Crankshaft TDC Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg.
    • Remove the Crankshaft TDC Timing Peg.
    Fig 7: Identifying Crankshaft TDC Timing Peg
    G07781885Courtesy of FORD MOTOR CO.
    10. NOTE: Measure the backlash and verify that it is within specified range at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. It will be necessary to reset the measuring equipment between measurements.
    NOTE: The measurement must be taken with the Dial Indicator Gauge with Holding Fixture, a 5-mm Allen wrench and worm clamp set up as shown in illustration. Mark the Allen wrench with a file 80 mm (3.149 in) above the driven gear shaft center. Make sure the worm clamp and Allen wrench are not touching the balance shaft housing.
    NOTE: For an accurate measurement while measuring the gear backlash, insert a screwdriver as shown in illustration into the crankshaft No. 1 crankweight area and set both the rotation and the thrust direction with the screwdriver, using a prying action as shown in illustration.
    Fig 8: Measuring Gear Backlash Using Dial Indicator Gauge With Specifications
    G07781886Courtesy of FORD MOTOR CO.
  10. Position the Dial Indicator Gauge with Holding Fixture as shown in illustration. Measure the gear backlash.
    • Position the Dial Indicator Gauge with Holding Fixture (1) on the Allen wrench 80 mm (3.149 in) above the driven gear shaft center (2) on the balancer unit.
    • Rotate the crankshaft clockwise and measure the backlash at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees.
    11. NOTE: If maximum backlash exceeds 0.101 mm (0.003 in), install a new balancer unit.
  11. Using the backlash measurement, select the proper shims from the Adjustment Shim Selection Table.
    • Remove the balancer unit from the cylinder block.
    • Install the selected adjustment shims on the seat faces of the balancer unit.
    ADJUSTMENT SHIM SELECTION TABLE

    Backlash mm (in) Selection shim (No.) Shim thickness mm (in)
    0.516-0.528 (0.0203-0.0207) 15 1.15 (0.0452)
    0.502-0.514 (0.0197-0.0202) 16 1.16 (0.0456)
    0.489-0.500 (0.0192-0.0196) 17 1.17 (0.0460)
    0.475-0.487 (0.0187-0.0191) 18 1.18 (0.0464)
    0.462-0.473 (0.0181-0.0186) 19 1.19 (0.0468)
    0.448-0.460 (0.0176-0.0181) 20 1.20 (0.0472)
    0.435-0.446 (0.0171-0.0175) 21 1.21 (0.0476)
    0.421-0.433 (0.0165-0.0170) 22 1.22 (0.0480)
    0.408-0.419 (0.0160-0.0164) 23 1.23 (0.0484)
    0.394-0.406 (0.0155-0.0159) 24 1.24 (0.0488)
    0.381-0.392 (0.0150-0.0154) 25 1.25 (0.492)
    0.367-0.379 (0.0144-0.0149) 26 1.26 (0.0496)
    0.354-0.365 (0.0139-0.0143) 27 1.27 (0.0499)
    0.340-0.352 (0.0133-0.0138) 28 1.28 (0.0503)
    0.327-0.338 (0.0128-0.0133) 29 1.29 (0.0507)
    0.313-0.325 (0.0123-0.0127) 30 1.30 (0.0511)
    0.300-0.311 (0.0118-0.0122) 31 1.31 (0.0515)
    0.286-0.298 (0.0112-0.0117) 32 1.32 (0.0519)
    0.272-0.284 (0.0107-0.0111) 33 1.33 (0.0523)
    0.259-0.271 (0.0101-0.0106) 34 1.34 (0.0527)
    0.245-0.257 (0.0096-0.0101) 35 1.35 (0.0531)
    0.232-.0243 (0.0091-0.0095) 36 1.36 (0.535)
    0.218-0.230 (0.0085-0.0090) 37 1.37 (0.539)
    0.205-.0216 (0.0080-0.0085) 38 1.38 (0.0543)
    0.191-0.203 (0.0075-0.0079) 39 1.39 (0.0547)
    0.178-0.189 (0.0070-0.0074) 40 1.40 (0.0551)
    0.164-0.176 (0.0064-0.0069) 41 1.41 (0.0555)
    0.151-0.162 (0.0059-0.0063) 42 1.42 (0.0559)
    0.137-0.149 (0.0053-0.0058) 43 1.43 (0.0562)
    0.124-0.135 (0.0048-0.0053) 44 1.44 (0.0566)
    0.110-0.122 (0.0043-0.0048) 45 1.45 (0.0570)
    0.097-0.108 (0.0038-0.0042) 46 1.46 (0.0574)
    0.083-0.095 (0.0032-0.0037) 47 1.47 (0.0578)
    0.070-0.081 (0.0027-0.0031) 48 1.48 (0.0582)
    0.056-0.068 (0.0022-0.0026) 49 1.49 (0.0586)
    0.043-0.054 (0.0016-0.0021) 50 (master) 1.50 (0.0590)
    0.029-0.041 (0.0011-0.0016) 51 1.51 (0.0594)
    0.015-0.027 (0.0005-0.0010) 52 1.52 (0.0598)
    0.002-0.014 (0.00007-0.0005) 53 1.53 (0.0602)
    0.000-0.000 (0.0000-0.0000) 54 1.54 (0.0606)
  12. Install the Crankshaft TDC Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at TDC.
    Fig 9: Identifying Crankshaft TDC Timing Peg
    G07781888Courtesy of FORD MOTOR CO.
  13. With the balancer unit shaft marks in the TDC position, slowly install the balancer unit to the cylinder block to avoid interference between the crankshaft drive gear and the balancer unit driven gear.
    Fig 10: Locating Balancer Unit And Shafts Reference Mark
    G07781889Courtesy of FORD MOTOR CO.
  14. Install the balancer unit bolts.
    • Tighten in the sequence shown in illustration in 2 stages.
    • Stage 1: Tighten to 25 Nm (18 lb-ft).
    • Stage 2: Tighten to 50 Nm (37 lb-ft).
    Fig 11: Identifying Balancer Unit Bolts Tightening Sequence
    G07781890Courtesy of FORD MOTOR CO.
    15. NOTE: Remeasure the backlash and verify that it is within specified range at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. It will be necessary to reset the measuring equipment between measurements.
    NOTE: The measurement must be taken with the Dial Indicator Gauge with Holding Fixture, a 5-mm Allen wrench and worm clamp set up as shown in illustration. Mark the Allen wrench with a file 80 mm (3.149 in) above the driven gear shaft center. Make sure the worm clamp and Allen wrench are not touching the balance shaft housing.
    NOTE: For an accurate measurement while measuring the gear backlash, insert a screwdriver as shown in illustration into the crankshaft No. 1 crankweight area and set both the rotation and the thrust direction with the screwdriver, using a prying action as shown in illustration.
  15. Position the Dial Indicator Gauge with Holding Fixture as shown in illustration. Measure the gear backlash.
Fig 12: Measuring Gear Backlash Using Dial Indicator Gauge With Specifications
G07781891Courtesy of FORD MOTOR CO.
scientia non olet · About LEMON Manuals