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Disassembly And Assembly: Axle: Assembly

WARNING: This page is about a different car, the 2005 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION: Do not omit the drive pinion bearing oil baffle; drive pinion bearing failure can result.
    Fig 1: Positioning Drive Pinion Bearing Oil Baffle On Special Tool
    G03928269Courtesy of FORD MOTOR CO.
  1. If removed, position the drive pinion bearing oil baffle on the special tool.
  2. Using the special tool, install the drive pinion bearing oil baffle.
    Fig 2: Installing Drive Pinion Bearing Oil Baffle Using Special Tool
    G03928352Courtesy of FORD MOTOR CO.
    3. NOTE: Always install new drive pinion bearings when installing new drive pinion bearing cups.
  3. Lightly oil the new drive pinion bearing cups and drive pinion bearings with axle lubricant.
  4. Using the special tool, install the drive pinion bearing cups.
    Fig 3: Installing Drive Pinion Bearing Cups Using Special Tool
    G03928271Courtesy of FORD MOTOR CO.
    5. NOTE: Apply only a light oil film on the drive pinion bearings before assembling the tools.
    Fig 4: Assembling Special Tools
    G03961163Courtesy of FORD MOTOR CO.
  5. Assemble and position the special tools.
    6. NOTE: This step duplicates final drive pinion bearing preload.
    Fig 5: Tightening Special Tool
    G03878601Courtesy of FORD MOTOR CO.
  6. Tighten the special tool.
    • Tighten to 2.2 Nm (20 lb-in).
    7. NOTE: The special tool must be offset to obtain an accurate reading.
    Fig 6: Rotating Special Tool Several Half-Turns To Make Sure Of Correct Seating Of Drive Pinion Bearings
    G03928274Courtesy of FORD MOTOR CO.
  7. Rotate the special tool several half-turns to make sure of correct seating of the drive pinion bearings and position the special tool.
  8. Install the special tool.
    1. Position the special tool.
    2. Install the differential bearing caps.
    3. Install the 4 differential bearing cap bolts.
      • Tighten to 105 Nm (77 lb-ft).
    Fig 7: Installing Special Tool
    G03928275Courtesy of FORD MOTOR CO.
    9. 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.
    Fig 8: Using Drive Pinion Bearing Adjustment Shim As A Gauge For Drive Pinion Bearing Adjustment Shim Selection
    G03878604Courtesy of FORD MOTOR CO.
  9. 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 all of the special tools.
    10. NOTE: You must use the same drive pinion bearings from the previous steps.
    Fig 9: Installing Inner Drive Pinion Bearing
    G03928278Courtesy of FORD MOTOR CO.
  10. Install the inner drive pinion bearing.
    • Place the drive pinion bearing adjustment shim on the drive pinion gear.
    • Using a suitable press and the special tool, press the inner drive pinion bearing until it is firmly seated on the pinion gear.
  11. Place a new drive pinion collapsible spacer on the drive pinion gear.
    Fig 10: Placing New Drive Pinion Collapsible Spacer On Drive Pinion Gear
    G03928265Courtesy of FORD MOTOR CO.
  12. Install the outer drive pinion bearing.
    Fig 11: Installing Outer Drive Pinion Bearing
    G03928015Courtesy of FORD MOTOR CO.
  13. Install the drive pinion oil slinger.
    Fig 12: Installing Drive Pinion Oil Slinger
    G03928281Courtesy of FORD MOTOR CO.
    14. NOTE: Coat the lips of the drive pinion seal with axle lubricant.
    Fig 13: Installing Drive Pinion Seal On Special Tool
    G03928282Courtesy of FORD MOTOR CO.
  14. Install the drive pinion seal on the special tool.
  15. Using the special tool, install the drive pinion seal.
    Fig 14: Using Special Tool To Install Drive Pinion Seal
    G03928283Courtesy of FORD MOTOR CO.
  16. Lightly lubricate the drive pinion gear splines with axle lubricant.
  17. Position the drive pinion gear in the axle housing.
    Fig 15: Positioning Drive Pinion Gear In Axle Housing
    G04583053Courtesy of FORD MOTOR CO.
    18. CAUTION: Never install the pinion flange with a hammer or power tools.
    NOTE: Disregard the scribe marks if installing a new pinion flange.
    Fig 16: Positioning Pinion Flange
    G03944236Courtesy of FORD MOTOR CO.
  18. Position the pinion flange.
    1. Align the index marks made during disassembly.
    2. Position the pinion flange on the drive pinion gear.
  19. Using the special tool, install the pinion flange.
    Fig 17: Installing Pinion Flange Using Special Tool
    G03928286Courtesy of FORD MOTOR CO.
  20. Apply a small amount of axle lubricant to the washer side of the new pinion nut, and install the new pinion nut.
    21. CAUTION: Do not loosen the pinion nut to reduce drive pinion bearing preload under any circumstance. If it is necessary to reduce drive pinion bearing preload, install a new drive pinion collapsible spacer and pinion nut.
    Fig 18: Installing Special Tool And Tightening Pinion Nut
    G03928261Courtesy of FORD MOTOR CO.
    Fig 19: Checking Pinion Bearing Preload Torque
    G03928225Courtesy of FORD MOTOR CO.
  21. Install the special tool, and tighten the pinion nut. Refer to the TORQUE SPECIFICATIONS .
    • Rotate the drive pinion gear occasionally to make sure the drive pinion bearings are seating correctly. Take frequent drive pinion bearing preload readings by rotating the drive pinion gear with a Nm (lb-in) torque wrench.
    22. CAUTION: Use extreme care not to damage the aluminum axle housing while carrying out the following procedure steps.
    CAUTION: The special tools are marked LH and RH. Install them accordingly.
    Fig 20: Installing Special Tools
    G03961179Courtesy of FORD MOTOR CO.
  22. Install the special tools.
  23. Install the differential assembly with the special tools in the axle housing.
    Fig 21: Installing Differential Assembly With Special Tools In Axle Housing
    G03928509Courtesy of FORD MOTOR CO.
    24. NOTE: Repeat this step until you obtain a consistent reading.
    Fig 22: Measuring Total End Play
    G03961181Courtesy of FORD MOTOR CO.
  24. Measure the total end play.
    1. Position the special tools.
    2. Position the indicator tip on the machined surface and adjust it to measure full travel.
    3. Push the differential assembly left and right (as far as possible).
    4. Measure the total end play and record the reading on the differential bearing shim selection procedure worksheet, line A, in this procedure.
  25. Remove the special tools and the differential assembly.
    Fig 23: Removing Special Tools And Differential Assembly
    G03928511Courtesy of FORD MOTOR CO.
  26. Use a fine flat file to remove any burrs or nicks from the differential ring gear mounting surface.
    Fig 24: Removing Burrs Or Nicks From Differential Ring Gear Mounting Surface
    G03928512Courtesy of FORD MOTOR CO.
  27. Install the differential ring gear.
    1. Position 3 differential ring gear bolts to align the holes in the differential ring gear and the differential assembly.
    2. Using a suitable press, install the differential ring gear.
    Fig 25: Installing Differential Ring Gear
    G03961184Courtesy of FORD MOTOR CO.
  28. Apply Stud and Bearing Mount to the threads of the differential ring gear bolts, then install the remaining differential ring gear bolts.
    • Tighten to 105 Nm (77 lb-ft).
    Fig 26: Identifying Differential Ring Gear Bolts
    G03878612Courtesy of FORD MOTOR CO.
  29. Remove 3 adjacent differential ring gear bolts.
    Fig 27: Removing Adjacent Differential Ring Gear Bolts
    G03928515Courtesy of FORD MOTOR CO.
    30. CAUTION: Position the 3 empty differential ring gear bolt holes downward.
    Fig 28: Positioning Differential Assembly With Special Tools Into Axle Housing
    G03961187Courtesy of FORD MOTOR CO.
  30. Position the differential assembly with the special tools into the axle housing.
  31. Position the special tools.
    Fig 29: Positioning Special Tools
    G03961188Courtesy of FORD MOTOR CO.
  32. Push and rock the differential ring gear into mesh with the drive pinion gear (zero backlash) and adjust the special tool to zero.
    Fig 30: Pushing Differential Ring Gear Into Mesh With Drive Pinion Gear (Zero Backlash)
    G03961189Courtesy of FORD MOTOR CO.
  33. Move the differential ring gear away from the drive pinion gear as far as possible. Record the reading on the differential bearing shim selection procedure worksheet, line B, in this procedure.
    Fig 31: Moving Differential Ring Gear Away From Drive Pinion Gear As Far As Possible
    G03928519Courtesy of FORD MOTOR CO.
  34. Remove the special tools.
    Fig 32: Removing Special Tools
    G03961188Courtesy of FORD MOTOR CO.
  35. Remove the differential assembly and the special tools.
    Fig 33: Removing Differential Assembly And Special Tools
    G03961187Courtesy of FORD MOTOR CO.
    36. NOTE: Measure both of the differential bearing stand heights prior to installing them on the differential assembly.
    NOTE: Mark the LH and RH differential bearings before measuring them.
    Fig 34: Clamping Special Tool Base In A Soft-Jawed Vise With Bearing Mounting Surface Above Surface Of Vise
    G03961193Courtesy of FORD MOTOR CO.
  36. Clamp the special tool base in a soft-jawed vise with the bearing mounting surface above the surface of the vise.
  37. Position the differential bearing assembly in the special tool, and tighten the tool.
    • Tighten to 2.8 Nm (25 lb-in).
    Fig 35: Positioning Differential Bearing Assembly In Special Tool And Tightening Tool
    G03961194Courtesy of FORD MOTOR CO.
  38. Measure the differential bearing stand height.
    1. Invert the special tool and bearing assembly in the vise.
    2. Use a depth micrometer to measure and record the differential bearing stand height.
    • Repeat the procedure for the other bearing.
    Fig 36: Measuring Differential Bearing Stand Height
    G03961195Courtesy of FORD MOTOR CO.
  39. Select appropriate differential bearing shims.
    DIFFERENTIAL BEARING SHIM SELECTION CHART

    8.8-inch Aluminum Axle Example Actual
    Line A - End play without ring gear 0.498  
    Line B - End play with ring gear (ring gear side) -0.245 Minus (-)
    Line C - Subtract Line B from Line A; also record on Line C, below 0.253  
    DIFFERENTIAL BEARING SHIM SELECTION CHART

    8.8-inch Aluminum Axle Left Differential Bearing Height Right Differential Bearing Height
    Example Actual Example Actual
    Master bearing height 0.8695 0.8695 0.8695 0.8695
    Line D - Actual bearing height -0.8478 minus (-) -0.8491 minus (-)
    Line E - Difference 0.0217   0.0204  
    DIFFERENTIAL BEARING SHIM SELECTION CHART

    8.8-inch Aluminum Axle Left Side 8.8-inch Aluminum Axle Right Side
    Example Actual Example Actual
    Line B - End play Line E-Bearing height 0.2450 +0.0217 + Line C - End play Line E-Bearing height 0.2530 +0.0204 +
    TOTAL - Lines B and E Backlash (subtract) 0.2667 -0.0060 -0.006 TOTAL - Lines C and E Backlash/preload (add) 0.2734 +0.020 +0.020
    Initial thickness (1) 0.2607   Initial thickness (1) 0.2934  
    Final shim thickness - left 0.261   Final shim thickness - right 0.293  
    (1) Round off initial thickness to the nearest shim thickness as in example for final shim thickness.
  40. Select the appropriate shim by the thickness or the stripe color.
    BACKLASH ADJUSTMENT AND DIFFERENTIAL BEARING SHIM SPECIFICATION

    Backlash Change Required Thickness Change Required
    mm In. mm In.
    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

    Stripes/Color mm In.
    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
    1- BLU 7.4930-7.5050 0.2950-0.2955
    5- PINK 7.4422-7.4549 0.2930-0.2935
    4- PINK 7.3914-7.4041 0.2910-0.2915
    3- PIK 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 6.9850-6.9977 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 0.2430-0.2335
    1- RED 6.1214-6.1341 0.2410-0.2415
    41. NOTE: Apply Stud and Bearing Mount to the threads of the differential ring gear bolts.
    Fig 37: Installing 3 Differential Ring Gear Bolts
    G03928515Courtesy of FORD MOTOR CO.
  41. Install the 3 differential ring gear bolts.
    • Tighten to 105 Nm (77 lb-ft).
    42. CAUTION: Press against the differential bearing inner core only.
    Fig 38: Using Suitable Press And Special Tool To Install Differential Bearings
    G03928371Courtesy of FORD MOTOR CO.
  42. Using a suitable press and the special tool, install the differential bearings.
    1. Position the appropriate differential bearing (RH or LH).
    2. Using a suitable press and the special tool, install the differential bearing.
    • Repeat the procedure for the other differential bearing.
    43. NOTE: Make sure the indicator needle is in the spreader adapter hole.
    Fig 39: Installing Special Tools
    G03961198Courtesy of FORD MOTOR CO.
  43. Install the special tools.
    44. CAUTION: Overspreading can damage the axle housing.
    Fig 40: Spreading Axle Housing To Specification
    G03928528Courtesy of FORD MOTOR CO.
  44. Spread the axle housing to the specification.
    • Remove the Dial Indicator.
    45. CAUTION: Never attempt to drive the differential bearing shim in place. Permanent damage to the machined axle housing surfaces can occur.
    Fig 41: Positioning Differential Bearing Shims
    G03928414Courtesy of FORD MOTOR CO.
  45. If removed, position the differential bearing shims.
    1. Apply a light coating of grease to one side of the differential bearing shims to help hold them in place.
    2. Position the differential bearing shims.
    46. NOTE: Push the differential assembly downward to fully seat the differential bearing cups in the axle housing.
    Fig 42: Positioning Differential Assembly
    G03928415Courtesy of FORD MOTOR CO.
  46. Position the differential assembly.
    1. Position the differential bearing cups on the differential bearings.
    2. Lower the differential assembly in place between the differential bearing shims.
  47. Install the differential bearing caps in their original positions and tighten with the housing still spread.
    1. Position the differential bearing caps.
    2. Install the 4 differential bearing cap bolts.
      • Tighten to 105 Nm (77 lb-ft).
    3. Remove the special tool.
    Fig 43: Installing Differential Bearing Caps In Their Original Positions And Tightening With Housing Still Spread
    G03928416Courtesy of FORD MOTOR CO.
  48. Install the special tool.
    Fig 44: Installing Special Tool
    G03961203Courtesy of FORD MOTOR CO.
  49. Measure the differential ring gear backlash at 4 places to obtain a consistent reading.
    Fig 45: Measuring Differential Ring Gear Backlash At 4 Places To Obtain Consistent Reading
    G03961204Courtesy of FORD MOTOR CO.
    50. NOTE: If the differential ring gear backlash is not within the specification, correct it by increasing the thickness of one differential bearing shim and decreasing the thickness on the other differential bearing shim by the same amount.
    Fig 46: Installing Thicker Differential Bearing Shim And Thinner Differential Bearing Shim
    G03928534Courtesy of FORD MOTOR CO.
  50. To increase the differential ring gear backlash, install a thicker differential bearing shim and a thinner differential bearing shim as shown.
  51. To decrease the differential ring gear backlash, install a thicker differential bearing shim and a thinner differential bearing shim as shown.
    Fig 47: Installing Thicker Differential Bearing Shim And Thinner Differential Bearing Shim
    G03928535Courtesy of FORD MOTOR CO.
    52. CAUTION: Remove all of the silicone gasket, and make sure the machined surfaces are free of oil before applying the new silicone gasket.
    CAUTION: Install the axle tube within 15 minutes of applying the silicone gasket or it will be necessary to remove and reapply a new silicone gasket. If possible, allow one hour before filling with lubricant to make sure the silicone gasket has cured.
    CAUTION: Do not allow any silicone gasket to squeeze inside during assembly.
    Fig 48: Installing Axle Tube
    G03961207Courtesy of FORD MOTOR CO.
  52. Install the axle tube.
    • Align the axle tube bolt holes and position the axle tube.
    • Position the axle identification tag.
    • Install the axle tube bolts.
      • Tighten to 73 Nm (54 lb-ft).
  53. Examine the axle shaft oil seal and axle shaft bearing surface for damage. If necessary, polish the axle shaft bearing surface with fine crocus cloth.
    Fig 49: Checking Axle Shaft Oil Seal And Axle Shaft Bearing Surface For Damage
    G03928537Courtesy of FORD MOTOR CO.
  54. Install a new retainer circlip on each axle shaft.
    Fig 50: Installing New Retainer Circlip On Each Axle Shaft
    G03928312Courtesy of FORD MOTOR CO.
  55. Insert the axle shafts and engage them with the differential side gears.
    Fig 51: Inserting Axle Shafts And Engaging With Differential Side Gears
    G03928313Courtesy of FORD MOTOR CO.
  56. Push in on the axle shafts until the retaining circlips expand in the differential side gears.
    Fig 52: Pushing On Axle Shafts Until Retaining Circlips Expand In Differential Side Gears
    G03928314Courtesy of FORD MOTOR CO.
  57. Remove the axle assembly from the special tool and place it on the bench.
    58. CAUTION: Remove all of the silicone gasket and make sure the machined surfaces are free of oil before applying the new silicone gasket.
    CAUTION: Install the differential housing cover within 15 minutes of applying the silicone gasket, or it will be necessary to remove and reapply silicone gasket. If possible, allow one hour before filling with lubricant to make sure the silicone gasket has cured.
    Fig 53: Filling Sealing Groove On Differential Housing Cover With Silicone Gasket
    G03928422Courtesy of FORD MOTOR CO.
  58. Fill the sealing groove on the differential housing cover with silicone gasket.
  59. Install the differential housing cover and the 10 differential housing cover bolts.
    • Tighten to 32 Nm (24 lb-ft).
    Fig 54: Installing Differential Housing Cover And 10 Differential Housing Cover Bolts
    G03928402Courtesy of FORD MOTOR CO.
  60. Fill the axle housing with axle lubricant and install the fill plug.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 55: Filling Axle Housing With Axle Lubricant
    G03928424Courtesy of FORD MOTOR CO.
  61. Install the axle assembly. For additional information, refer to AXLE ASSEMBLY .
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