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Ring Gear Backlash Adjustment

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SPECIAL TOOLS

G07950734
 Dial Indicator Gauge With Holding Fixture
100-002 (TOOL-4201-C)
G06125115
 Installer, Differential Shim
205-220 (T85L-4067-AH)
MATERIAL SPECIFICATIONS

Item Specification
Motorcraft® High Contrast Hypoid Gear Marking Compound
XG-14		 -
  1. Remove the differential housing cover. For additional information, refer to DIFFERENTIAL HOUSING COVER .
  2. Install the Dial Indicator Gauge with Holding Fixture and measure the ring gear backlash.
    • If a zero backlash condition occurs or the backlash is not within specification, proceed to Step 3.
    • If the backlash is within specification, proceed to Step  14.
      Fig 1: Measuring Ring Gear Backlash Using Dial Indicator Gauge
      G06166719Courtesy of FORD MOTOR CO.
  3. Remove the axle shafts. For additional information, refer to AXLE SHAFT .
  4. NOTE: Index-mark the position of the differential bearing caps, as arrows may not be visible. The differential bearing caps must be installed in their original locations and positions.

    Remove the 4 differential bearing cap bolts and 2 caps.

    Fig 2: Locating Differential Bearing Cap Bolts
    G06166720Courtesy of FORD MOTOR CO.
  5. If a zero backlash condition had occurred, 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. Install the 2 bearing caps and 4 bolts.
    • Tighten to 122 Nm (90 lb-ft).
    • Go back to Step  2.
  6. 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.
    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
  7. Install the 2 differential bearing caps and 4 bolts.
    • Tighten to 122 Nm (90 lb-ft).
      Fig 3: Locating Differential Bearing Caps And Bolts
      G06166720Courtesy of FORD MOTOR CO.
  8. Using the Dial Indicator Gauge with Holding Fixture, recheck the ring gear backlash.
    • If backlash is now within specification, proceed to Step 9.
    • If backlash is not within specification, go back to Step  4.
      Fig 4: Measuring Ring Gear Backlash Using Dial Indicator Gauge
      G06166719Courtesy of FORD MOTOR CO.
  9. Remove the 4 bearing cap bolts and 2 bearing caps.
  10. To establish differential bearing preload, increase both LH and RH differential bearing shim size by the thickness shown in illustration.
    Fig 5: Identifying LH And RH Differential Bearing Shim Size
    G06166923Courtesy of FORD MOTOR CO.
  11. Using the Differential Shim Installer, fully seat the differential bearing shims. Make sure the assembly rotates freely.
    Fig 6: Seating Differential Bearing Shims Using Differential Shim Installer
    G06166724Courtesy of FORD MOTOR CO.
  12. Install the 2 differential bearing caps and 4 bolts.
    • Tighten to 122 Nm (90 lb-ft).
      Fig 7: Locating Differential Bearing Caps And Bolts
      G06166720Courtesy of FORD MOTOR CO.
  13. Using the Dial Indicator Gauge with Holding Fixture, do a final check of the ring gear backlash.
    Fig 8: Checking Ring Gear Backlash Using Dial Indicator Gauge
    G06166719Courtesy of FORD MOTOR CO.
  14. Apply marking compound and rotate the differential assembly 5 complete revolutions.
  15. Verify an acceptable pattern check. For additional information, refer to Tooth Contact Pattern Check in DRIVELINE SYSTEM - GENERAL INFORMATION .
  16. Install the axle shafts. For additional information, refer to AXLE SHAFT .
  17. Install the differential housing cover. For additional information, refer to DIFFERENTIAL HOUSING COVER .
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