Differential Bearings: Installation
- If removed, install the drive pinion oil baffle.
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NOTE: Make sure the drive pinion bearing cups are seated correctly or damage to the components may occur.
Using the special tools, install the new outer drive pinion bearing cup.
Use Special Service Tool: 205-153 (T80T-4000-W) Handle, 205-1024 Installer, Outer Pinion Bearing Cup.
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NOTE: Use the same drive pinion bearings and the drive pinion bearing adjustment shim from the drive pinion bearing adjustment shim selection procedure for final assembly or damage to the component may occur.NOTE: Install new drive pinion bearings without any additional lubricant since the anti-rust oil provides adequate lubricant without upsetting the drive pinion bearing preload settings.
Assemble the special tools using the new outer drive pinion bearing.
Use Special Service Tool: 205-159 (T80T-4020-F42) Adapter for 205-S156 Pinion Depth Gauge, 205-160 (T80T-4020-F43) Adapter for 205-S156 Pinion Depth Gauge, 205-129 (T79P-4020-A18) Disc, Gauge, 205-281 (T88T-4020-B) Depth Gauge/Aligner, Drive Pinion (Handle), 205-1019 Dummy Pinion Bearing.
Torque: 19 lb.in (2.2 Nm)
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- Tighten special tools and check for clear rotation.
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NOTE: This step duplicates final drive pinion bearing preload.
Tighten the special tool to the specified torque.
Torque: 18 lb.in (2 Nm)
- Slowly rotate and record the rotational torque readings.
- Install the special tool, the differential bearing caps and the differential bearing cap bolts.
Use Special Service Tool:205-D033 (D80T-4020-F48) Gauge Tube (3.8135).
Torque: 80 lb.ft (108 Nm)
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NOTE: Drive pinion bearing adjustment shims must be flat and clean.NOTE: A slight drag should be felt for correct drive pinion bearing adjustment shim selection. Do not attempt to force the drive pinion bearing adjustment shim between the gauge block and the gauge tube. This will minimize selection of a drive pinion bearing adjustment shim thicker than required, which results in a deep tooth contact in final assembly of integral axle assemblies.
Use a drive pinion bearing adjustment shim as a gauge for drive pinion bearing adjustment shim selection.
- After the correct drive pinion bearing adjustment shim thickness has been determined, remove the special tools.
- Notice the (+) or (-) etching on the pinion, and adjust the new shim thickness to compensate for the difference of these 2 figures.
- 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.
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NOTE: Make sure the drive pinion bearing cups are seated correctly or damage to the components may occur.
Using the special tools, install the new inner drive pinion bearing cup and the selected pinion depth shim.
Use Special Service Tool: 205-098 (T75T-1176-A) Drawbar, Rear Axle, 205-1023 Installer, Inner Pinion Bearing Cup,205-1024 Installer, Outer Pinion Bearing Cup.
- Install the drive pinion bearing until it is firmly seated on the drive pinion.
Use Special Service Tool: 205-090 (T75L-1165-B) Plate, Bearing/Oil Seal, 205-092 (T75L-1165-DA) Installer, Rear Axle Bearing/Oil Seal.
Use the General Equipment: Hydraulic Press
- Install the pinion gear.
- Install the new drive pinion collapsible spacer.
- Install the outer drive pinion bearing.
- Install the outer drive pinion oil slinger.
- Install the drive pinion flange and seal. REFER to: Drive Pinion Flange and Seal .
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NOTE: It is necessary to loosely install the bearing caps and bolts to hold the differential in place.
Position the differential case with the Dummy Bearing Set into the differential housing.
Use Special Service Tool: 205-D047 (D81T-4222-DR) Set, Dummy Bearing.
- Loosely install the differential bearing caps.
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NOTE: Repeat this step until there is a consistent reading.
Using the Dummy Bearing Set, Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, determine the total thickness of differential bearing shims to install under the differential bearing on the ring gear side of the differential case. Record this measurement, as the shim thickness required for the ring gear side of the differential case.
- Force the ring gear away from the pinion and zero the Dial Indicator Gauge.
- Force the ring gear into mesh with the pinion. Rock the ring gear to allow the teeth of the gears to mesh.
- Record the reading.
- Remove the differential case and the Dummy Bearing Set from the differential housing.
- Remove the Dummy Bearing Set from the differential case.
- Place the required thickness of differential bearing shims on the ring gear side of the differential case. Refer to the measurement recorded, as the shim thickness required for the ring gear side of the differential case.
- For example, a reading of 1.14 mm (0.045 in), requires that 1.14 mm (0.045 in) shims be placed on the ring gear side of the differential case. For available differential bearing shims. REFER to: SPECIFICATIONS .
- Using the Differential Carrier Bearing Installer, install the differential bearing.
- Determine the total thickness of differential bearing shims to install under the differential bearing on the drive pinion side of the differential case.
- Subtract the measurement recorded, as the shim thickness required for the ring gear side of the differential case, from the total case end play measurement taken at the beginning of the assembly procedure. Then, add 0.38 mm (0.015 in) to the total. This is the total amount of differential bearing shims to install under the differential bearing on the drive pinion side of the differential case.
- Place the amount of differential bearing shims, as determined by the calculation made in the previous step, on the drive pinion side of the differential case.
- Using the Differential Carrier Bearing Installer and Step Plate, install the differential bearing.
- Place the Step Plate under the bearing to protect it during the bearing installation.
- Using the Differential Carrier Bearing Installer, install the bearing.
- Position the differential bearing cups on the bearings.
- Position the differential assembly in the axle housing.
- Install the bearing caps and the bolts.
Torque: 80 lb.ft (108 Nm)
- Using the general equipment, measure the backlash at 3 equally spaced points.
- The backlash must be within the specifications and cannot vary more than 0.05 mm (0.002 in) between points checked.
- Make the necessary corrections by moving shims from one side of the differential case to the other, until the correct backlash adjustment is achieved.
- Correct for low backlash by moving the ring gear away from the pinion.
- Correct for high backlash by moving the ring gear toward the pinion.
- Apply marking compound and rotate the differential assembly 5 complete revolutions.
- Verify an acceptable pattern check. REFER to: Front Drive Axle .
- Clean the gasket material from the differential housing and the differential housing cover.
- Apply a new continuous bead of sealant to the differential housing cover as shown in illustration.
Material: Motorcraft® Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)
- Install the differential cover and differential cover bolts.
Torque: 45 lb.ft (61 Nm)
- Install the axle shafts and seals. REFER to: Axle Shaft Seal .
- Check the front differential fluid level. REFER to: Differential Fluid Level Check .