Balance Shaft Backlash

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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	303-1688 Preload Tool, Balance Shaft
Courtesy of FORD MOTOR COMPANY	303-507 Timing Peg, Crankshaft TDC TKIT-2001N-FLM TKIT-2001N-ROW

Check 

1. Install the special tool 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. Use Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.

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

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3. Remove the bolts and the oil outlet tube.

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4. Inspect the oil outlet tube O-ring seals and replace if damaged.

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5. 1. Remove the oil inlet tube-to-bracket bolt.
   2. Remove the bolt and the oil inlet tube bracket.
   3. Remove the bolts and the oil inlet tube.

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6. Inspect the oil inlet tube O-ring seals and replace if damaged.

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

   Remove the bolts and the balance unit.

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8. Remove the adjustment shims from the seat faces of the balancer unit.

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9. 1. Visually inspect the balancer unit gear for damage.
   2. Verify that the shaft turns smoothly.
   • If there is any damage or malfunction, replace the balancer unit.

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10. Install the master adjustment shims No. 50 on the seat faces of the balancer unit.

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11. 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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12. Install the bolts and tighten in sequence shown.

    Torque: Stage 1: 27 lb.ft (36 Nm) - - Stage 2: 60°

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13. Loosen the bolts.

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14. Tighten the bolts in sequence shown.

    Torque: Stage 1: 133 lb.in (15 Nm) - - Stage 2: 45°

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15. Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.

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16. Rotate the crankshaft to confirm that there are no meshing problems between the balancer unit gear and the crankshaft gear.

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17. Install the special tool 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. Use Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.

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18. Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.

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19. 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.
    • NOTE: Make sure the worm clamp and Allen wrench are not touching the balance shaft housing.

      Install the 5-mm Allen wrench and tighten worm clamp as shown.

    • Mark the Allen wrench with a file 20 mm (0.79 in) above the driven gear top surface.
    • Install the balance shaft preload tool and bolts as shown. Use Special Service Tool: 303-1688 Preload Tool, Balance Shaft.
    • Install and position the dial indicator gauge with holding fixture on the Allen wrench 20 mm (0.79 in) as shown. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
    • 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.

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20. 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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21. Remove the bolts and the balance unit.

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22. Remove the master adjustment shims (No. 50) from the balancer unit.

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23. Install the selected adjustment shims on the seat faces of the balancer unit from the chart above.

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24. Install the special tool 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. Use Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.

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25. 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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26. Install the bolts and tighten in sequence shown.

    Torque: Stage 1: 133 lb.in (15 Nm) - - Stage 2: 45°

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27. Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.

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28. 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.
    • NOTE: Make sure the worm clamp and Allen wrench are not touching the balance shaft housing.

      Install the 5-mm Allen wrench and tighten worm clamp as shown.

    • Mark the Allen wrench with a file 20 mm (0.79 in) above the driven gear top surface.
    • Install the balance shaft preload tool and bolts as shown. Use Special Service Tool: 303-1688 Preload Tool, Balance Shaft.
    • Install and position the dial indicator gauge with holding fixture on the Allen wrench 20 mm (0.79 in) as shown. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
    • 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 0.040 to 0.140 mm (0.00157 to 0.0055 in), install a new balancer unit and repeat the procedure.

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29. Lubricate the oil inlet tube O-ring seals with clean engine oil.

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30. 1. Install the oil inlet tube and the bolts.

       Torque: 97 lb.in (11 Nm)

    2. Install the oil inlet tube bracket and the bolt.

       Torque: 97 lb.in (11 Nm)

    3. Install the oil inlet tube-to-bracket bolt.

       Torque: 97 lb.in (11 Nm)

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31. Lubricate the oil outlet tube O-ring seals with clean engine oil.

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32. Install the oil outlet tube and the bolts.

    Torque: 97 lb.in (11 Nm)

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