Differential Bearings: Installation

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Position the inner and outer pinion bearing cups and the Rear Axle Drawbar, Drive Pinion Bearing Cup Installers in their respective axle housing bores.
1. After placing the inner and outer pinion bearing cups in their bores, place the Drive Pinion Bearing Cup Installer (inner) on the inner pinion bearing cup.
2. Place the Drive Pinion Bearing Cup Installer (outer) on the outer pinion bearing cup.
3. Install the Rear Axle Drawbar.
  
  Fig 1: Identifying Rear Axle Drawbar
  Courtesy of FORD MOTOR CO.
Tighten the Rear Axle Drawbar to seat the pinion bearing cups into their bores.

Fig 2: Tightening Rear Axle Drawbar
Courtesy of FORD MOTOR CO.
NOTE: If the feeler gauge can fit between a pinion bearing cup and the bottom of its bore at any point around the pinion bearing cup, remove and reseat the pinion bearing cup.

Check that the pinion bearing cups have seated correctly in their bores.

Fig 3: Checking Pinion Bearing Cup Seating Position
Courtesy of FORD MOTOR CO.
NOTE: Remove all nicks, burrs and dirt from the differential carrier hubs to allow the differential bearings to rotate freely.

Place the 0.762 mm (0.030 in) inboard shim and the Dummy Bearing Set on the differential carrier hubs. Position the differential carrier into the axle housing.

Fig 4: Placing Differential Assembly With Dummy Bearing Set In Differential Housing
Courtesy of FORD MOTOR CO.
NOTE: Use a Dial Indicator Gauge with a minimum travel capability of 5.08 mm (0.200 in).

Mount the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge as shown below. Locate the tip of Clutch Housing Gauge on the flat surface of one of the differential ring gear bolts.

Fig 5: Identifying Dial Indicator Gauge With Holding Fixture And Clutch Housing Gauge
Courtesy of FORD MOTOR CO.
NOTE: Repeat this step and the following step until the same reading appears on the Dial Indicator Gauge each time. Record the reading. This is the total differential bearing shim thickness required, less preload. The final calculation occurs later during assembly.

Force the differential carrier as far as possible toward the Dial Indicator Gauge. With force still applied, zero the Dial Indicator Gauge.

Fig 6: Forcing Differential Case And Ring Gear Away From Drive Pinion
Courtesy of FORD MOTOR CO.
Force the differential carrier as far as it will go in the opposite direction. Record the total differential carrier end play reading.

Fig 7: Forcing Differential Ring Gear Into Mesh With Pinion
Courtesy of FORD MOTOR CO.
After making sure the reading is consistent, remove the differential carrier from the axle housing. Do not remove the Dummy Bearing Set from the differential carrier at this time.
NOTE: If any of the gauge surfaces have nicks in them, remove the high spots with a medium India oilstone to prevent erroneous readings.

NOTE: Apply only a light oil film on the pinion bearings before assembling the tools.

Assemble and position the following in the differential housing.
1. Position the Adapter.
2. Position the Alignment Adapter.
3. Position the inner pinion bearing.
4. Position the Drive Pinion Depth Gauge/Aligner.
5. Position the Adapter.
6. Position the outer pinion bearing.
7. Thread on the Handle.
  
  Fig 8: Positioning Inner And Outer Pinion Bearing In Differential Housing
  Courtesy of FORD MOTOR CO.
Install the Gauge Tube.
1. Install the 2 differential bearing caps.
2. Install the 4 differential bearing cap bolts.
  - Tighten to 108 Nm (80 lb-ft).
    
    Fig 9: Installing Gauge Tube
    Courtesy of FORD MOTOR CO.

NOTE: Use the thickness of the old drive pinion bearing preload shims as a starting point for setting pinion bearing preload.

Inspect the drive pinion bearing preload shim for damage. Discard it if necessary. New drive pinion bearing preload shims are available in the thickness shown in the following chart.

AVAILABLE INNER DRIVE PINION BEARING SHIMS

mm	Inches
0.36	0.014
0.38	0.015
0.41	0.016
0.46	0.018
0.51	0.020
0.53	0.021
0.56	0.022
0.58	0.023
0.76	0.030

NOTE: Use a feeler gauge or flat, clean drive pinion position shim as a measuring device.

NOTE: Do not attempt to force the gauge or drive pinion position shim between the Gauge Tube and Adapter. A slight drag indicates a correct selection.

Using a feeler gauge or flat, clean drive pinion position shim, measure between the Adapter and Gauge Tube. Record the measurement.

Fig 10: Measuring Between Adapter And Gauge Tube
Courtesy of FORD MOTOR CO.
Notice the (+) or (-) etching on the pinion and adjust the new shim thickness to compensate for the difference of these 2 figures. If equipped, include the oil slinger thickness in the total measurement to correctly set pinion depth.
- For example, a pinion etched with m+8 (+3) requires 0.08 mm (0.003 in) less shimming than a pinion etched "0". This means to increase the mounting distance by the amount etched in the pinion, subtract 0.08 mm (0.003 in) from the drive pinion position shim selected for installation. A pinion etched m-8 (-3), requires 0.08 mm (0.003 in) more shimming than a pinion etched "0". In this instance, add 0.08 mm (0.003 in) to the drive pinion position shim selected for installation to decrease the pinion mounting distance by the amount etched in the pinion.
NOTE: Always use the same new inner pinion bearing installed when taking the measurement for drive pinion shim selection.

NOTE: Position the selected pinion depth shim on the pinion shaft between the inner bearing and the pinion head.

Using the Bearing/Oil Seal Plate and Drive Pinion Bearing Installer and a suitable press, install the pinion bearing.

Fig 11: Installing Pinion Bearing
Courtesy of FORD MOTOR CO.
Install the outer pinion bearing and drive pinion oil slinger.
Position the original pinion bearing preload shims on the pinion and install the pinion gear in the pinion gear bore from the rear of the housing.
NOTE: The pinion flange must never be hammered on or installed with power tools or damage to the component may occur.

Using the Drive Pinion Flange Installer, install the pinion flange.

Fig 12: Installing Pinion Flange
Courtesy of FORD MOTOR CO.
Use the Drive Pinion Flange Holding Fixture to prevent the pinion flange from turning while installing the old washer and the pinion shaft locknut.
- Tighten to 637 Nm (470 lb-ft).
  
  Fig 13: Holding Pinion Flange
  Courtesy of FORD MOTOR CO.
Using a Nm (lb-in) torque wrench, rotate the pinion. The rotational torque must read 2.3-4.5 Nm (20-40 lb-in).
- To increase the drive pinion bearing preload, remove drive pinion bearing preload shims. To decrease the drive pinion bearing preload, add drive pinion bearing shims.
  
  Fig 14: Checking Pinion Turning Torque
  Courtesy of FORD MOTOR CO.
While using the Drive Pinion Flange Holding Fixture to prevent the pinion flange from turning, remove and discard the old washer and pinion shaft locknut.

Fig 15: Holding Pinion Flange
Courtesy of FORD MOTOR CO.
Using the 2 Jaw Puller, remove the pinion flange.

Fig 16: Removing Pinion Flange Using Jaw Puller
Courtesy of FORD MOTOR CO.
NOTE: If the drive pinion seal becomes cocked during installation, remove and install a new one. Make sure the garter spring remains in place during assembly. If the spring is dislodged, a new drive pinion seal must be installed.

Using the Drive Pinion Oil Seal Installer, drive the pinion seal into the housing.
- Coat the pinion seal (rubber lips) with axle lubricant.
  
  Fig 17: Installing Pinion Seal
  Courtesy of FORD MOTOR CO.
NOTE: The pinion flange must never be hammered on or installed with power tools or damage to the component may occur.

Using the Drive Pinion Flange Installer, install the pinion flange.

Fig 18: Installing Pinion Flange
Courtesy of FORD MOTOR CO.
Using the Drive Pinion Flange Holding Fixture, prevent the pinion flange from turning while installing the new washer and pinion shaft locknut.
- Tighten to 637 Nm (470 lb-ft).
  
  Fig 19: Holding Pinion Flange
  Courtesy of FORD MOTOR CO.
Using a Nm (lb-in) torque wrench, rotate the pinion. The rotational torque must read 0.6 Nm (5 lb-in) higher than previously recorded with the new pinion seal installed.

Fig 20: Checking Pinion Turning Torque
Courtesy of FORD MOTOR CO.
Position the differential carrier assembly with the Dummy Bearing Set in the axle housing. Install the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge and locate the tip of Clutch Housing Gauge on a flat surface.

Fig 21: Identifying Dial Indicator Gauge With Holding Fixture And Clutch Housing Gauge
Courtesy of FORD MOTOR CO.
NOTE: Repeat this step and the following step until the same reading appears on the Dial Indicator Gauge each time. This is the differential bearing shim thickness necessary between the differential case and the differential bearing on the differential ring gear side of the differential case.

Force the differential case away from the drive pinion. With force still applied, set the Dial Indicator Gauge to zero.

Fig 22: Forcing Differential Case And Ring Gear Away From Drive Pinion
Courtesy of FORD MOTOR CO.
Force the differential ring gear into mesh with the pinion to obtain the Dial Indicator Gauge reading. Record the reading.

Fig 23: Forcing Differential Ring Gear Into Mesh With Pinion
Courtesy of FORD MOTOR CO.
Remove the differential case from the differential housing.
Remove the Dummy Bearing Set from the differential case.
- Make sure the inner bearing shims remain on the differential carrier hubs.
Install the original outboard spacers in the side from which they were removed.

Fig 24: Installing Outboard Spacers
Courtesy of FORD MOTOR CO.
Using the Differential Carrier Bearing Installer, install the differential bearing and shim on the LH side of the differential case.

Fig 25: Installing Differential Bearing On Differential Case
Courtesy of FORD MOTOR CO.
Using the Differential Carrier Bearing Installer and Differential Carrier Bearing Step Plate, install the differential bearing.
1. Place the Differential Carrier Bearing Step Plate on the differential bearing to protect it during the installation of the opposite bearing.
2. Using the Differential Carrier Bearing Installer, drive the differential bearing onto the hub.
  
  Fig 26: Installing Differential Bearing
  Courtesy of FORD MOTOR CO.
Assemble the differential bearing cups to the differential bearings.
Place one outboard spacer of the necessary thickness, as determined from the previous measurement, on the LH side of the differential housing.
Determine the correct outboard spacer thickness and place it on the differential case hub on the RH side.
- To determine the correct spacer thickness, first, subtract the reading of the previous measurement from the total differential case end play reading. Then, add 0.25 mm (0.010 in) to this amount. This is the correct thickness spacer to place on RH side of the housing.
NOTE: Do not spread the differential housing more than specified or damage to the housing may occur.

NOTE: Avoid nicking the ring gear teeth and the anti-lock speed sensor ring during assembly or damage to the component may occur.

Using the Differential Carrier Spreader and Dial Indicator Gauge with Holding Fixture, spread the differential housing to the specification.
- Use a rawhide hammer to seat the differential into the differential housing pocket.
  
  Fig 27: Spreading Differential Housing Using Differential Carrier Spreader And Dial Indicator Gauge With Holding Fixture
  Courtesy of FORD MOTOR CO.
NOTE: Match the mating letters as noted during disassembly.

Install the 2 bearing caps and 4 bolts, aligning the letters with those on the differential housing.
- Tighten to 108 Nm (80 lb-ft).
  
  Fig 28: Locating Mating Letters Stamped On Bearing Caps And Differential Housing
  Courtesy of FORD MOTOR CO.
Confirm the total preload.
- Using a Nm (lb-in) torque wrench, check the torque to rotate the pinion. The reading must be higher than the initial reading (taken without the differential carrier installed) with new bearings installed as recommended by the following:
  - 3.54 and 3.73 = 0.9 Nm (8 lb-in)
  - 4.10 and 4.56 = 0.8 Nm (7 lb-in)
  - 4.63 and 5.13 = 0.8 Nm (7 lb-in)
- If the total preload is too high, remove an equal amount of differential bearing shims from each differential case hub. If the total preload is too low, add an equal amount of differential bearing shims to each differential case hub.
  
  Fig 29: Checking Pinion Turning Torque
  Courtesy of FORD MOTOR CO.
Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, measure the differential ring gear and pinion backlash at 3 equally spaced points.

Fig 30: Measuring Differential Ring Gear And Pinion Backlash
Courtesy of FORD MOTOR CO.
Carry out the tooth contact pattern check to verify that the final pinion position is correct. For additional information, refer to DRIVELINE SYSTEM - GENERAL INFORMATION .
Install the axle shafts. For additional information, refer to WHEEL HUBS AND BEARINGS - FULL FLOATING AXLE - DANA .
NOTE: Align the index marks made during removal.

Position the driveshaft flange on the axle pinion flange and install the 4 new bolts.
- Tighten to 100 Nm (74 lb-ft).
  
  Fig 31: Locating Index-Mark On Driveshaft Flange And Pinion Flange
  Courtesy of FORD MOTOR CO.
Clean the gasket mating surface of the axle and the differential housing cover.
NOTE: Install the differential cover within 15 minutes of applying the silicone or it will be necessary to remove and reapply new sealant.

Apply a continuous bead of sealant to the differential housing cover as shown below.

Fig 32: Identifying Continuous Bead Of Sealant Applying Dimension On Differential Housing Cover
Courtesy of FORD MOTOR CO.
Install the differential housing cover and the 10 bolts.
- Tighten alternately and evenly to 45 Nm (33 lb-ft).
  
  Fig 33: Locating Differential Housing Cover Bolts
  Courtesy of FORD MOTOR CO.
NOTE: If possible, allow an hour before filling with lubricant to make sure the silicone sealant has correctly cured.

Fill the axle with the specified type and amount of lubricant.