Balance Shaft Backlash

For information on Ford Color Coded Illustrations refer to OEM COLOR CODING

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge
Courtesy of FORD MOTOR COMPANY	303-507 Timing Peg, Crankshaft TDC TKIT-2001N-FLM TKIT-2001N-ROW

Check 

1. Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at TDC. Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.

   Courtesy of FORD MOTOR COMPANY

2. Mark the balancer unit and shafts on the top for reference that the balancer unit is at TDC.

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3. NOTE: Due to the precision interior construction of the balancer unit, it should not be disassembled.

   Remove the bolts and the balancer unit.

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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.

   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.

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7. Install the balancer unit bolts, tighten in sequence shown in 2 stages.

   Torque

   :Stage 1: 18 lb.ft (25 Nm) Stage 2: 31 lb.ft (42 Nm)

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8. Rotate the crankshaft to confirm that there are no meshing problems between the balancer unit gear and the crankshaft gear. Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.

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9. Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at TDC. Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.

   Courtesy of FORD MOTOR COMPANY

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. 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 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.
    • Position as shown. Measure the gear backlash. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
    • 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.

    Courtesy of FORD MOTOR COMPANY

11. Using the backlash measurement, select the proper shims from the Adjustment Shim Selection Table.
    1. Backlash
    2. Selection shim (No.)
    3. Shim thickness

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12. • Remove the balancer unit from the cylinder block.
    • Install the selected adjustment shims on the seat faces of the balancer unit.

13. Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at TDC. Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.

    Courtesy of FORD MOTOR COMPANY

14. 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.

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15. Install the balancer unit bolts, tighten in sequence shown in 2 stages.

    Torque

    :Stage 1: 18 lb.ft (25 Nm) Stage 2: 31 lb.ft (42 Nm)

    Courtesy of FORD MOTOR COMPANY

16. 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. 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 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.
    • Position as shown. Measure the gear backlash. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
    • 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.
    • If the backlash exceeds the specified range of 0.020 to 0.120 mm (0.00078 to 0.0047 in), install a new balancer unit and repeat the procedure.

Courtesy of FORD MOTOR COMPANY