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Disassembly And Assembly: Axle: Assembly

WARNING: This page is about a different variant/trim than selected.
    CAUTION: A new oil baffle must be installed located between the inner drive pinion bearing cup and the axle housing bore.
    Fig 1: Installing Oil Baffle, Inner And Outer Drive Pinion Bearing Cups
    G02743599Courtesy of FORD MOTOR CO.
  1. Using the special tool, install a new oil baffle, inner and the outer drive pinion bearing cups.
    • Apply a light coat of rear axle lubricant to the drive pinion bearing cup bore.
  2. Install the special tools, inner and outer drive pinion bearings.
    • Preload the drive pinion bearings.
    Fig 2: Installing Special Tools, Inner And Outer Drive Pinion Bearings
    G02743600Courtesy of FORD MOTOR CO.
    3. NOTE: The special tool must be offset to obtain an accurate reading.
    NOTE: Rotate the special tool several half turns to correctly seat the drive pinion bearings.
    Fig 3: Positioning Special Tool At 45 Degrees
    G02743601Courtesy of FORD MOTOR CO.
  3. Position the special tool at 45 degrees as shown.
  4. Install the special tool.
    1. Position the special tool.
    2. Position the bearing caps.
    3. Install the bolts.
    Fig 4: Installing Special Tool, Bearing Caps & Bolts
    G02743602Courtesy of FORD MOTOR CO.
    5. CAUTION: If the drive pinion is marked with a plus (+) reading, this amount must be subtracted from the thickness measured. If the drive pinion is marked with a minus (-) reading, this amount must be added to the thickness measured.
    Fig 5: Measuring Clearance Between Gauge Tube And Gauge Block
    G02743603Courtesy of FORD MOTOR CO.
  5. Measure and record the clearance between the gauge tube and the gauge block.
    • Select and check the correct drive pinion position shim as necessary.
    6. CAUTION: The same drive pinion bearings and drive pinion bearing cups used in the drive pinion position shim selection procedure must be used in the final axle assembly.
    Fig 6: Installing Drive Pinion Position Shim And Bearing Onto Drive Pinion
    G02743604Courtesy of FORD MOTOR CO.
  6. Using the special tools, install the drive pinion position shim and the bearing onto the drive pinion.
    1. Position the drive pinion position shim.
    2. Position the drive pinion bearing.
    3. Position the special tools.
    4. Using a press, firmly seat the drive pinion bearing on the drive pinion.
    7. CAUTION: Do not reuse the old collapsible spacer.
    Fig 7: Installing Collapsible Spacer
    G02743605Courtesy of FORD MOTOR CO.
  7. Install a new collapsible spacer.
  8. Using the special tools, install the drive pinion and a new drive pinion nut.
    • Rotate the drive pinion counterclockwise until all end play is removed then tighten the drive pinion nut.
    Fig 8: Installing Drive Pinion And Drive Pinion Nut
    G02743606Courtesy of FORD MOTOR CO.
    9. CAUTION: If the rotational torque is less than specification, tighten the drive pinion nut in small increments until it is within specification. Do not tighten the drive pinion nut more than 678 Nm (500 lb-ft) or the collapsible spacer will be damaged. If the rotation torque is higher than specification, the collapsible spacer has been compressed too far and a new collapsible spacer must be installed.
    NOTE: When tightening the drive pinion nut to remove initial end play, torque may exceed the maximum specification. Once end play is removed and the collapsible spacer has started to collapse, the torque should drop into the specified range.
    NOTE: Rotate the drive pinion 10 revolutions before taking the reading.
    Fig 9: Checking Drive Pinion Rotational Torque And Adjust
    G02743607Courtesy of FORD MOTOR CO.
  9. Check the drive pinion rotational torque and adjust as necessary.
    10. NOTE: The differential case should move freely in the axle housing.
    Fig 10: Installing Differential Case Into Axle Housing
    G02743608Courtesy of FORD MOTOR CO.
  10. Using the special tools, install the differential case into the axle housing.
    11. NOTE: Repeat this step until a same reading is obtained twice.
    Fig 11: Measuring Differential Case Total End Play
    G02743609Courtesy of FORD MOTOR CO.
  11. Seat the differential case away from the drive pinion then push the differential case toward the drive pinion while measuring and recording the differential case total end play.
    12. NOTE: Take note which side each special tool was removed from so they can be installed on the same side of differential case for the next measurement with the ring gear installed.
    Fig 12: Removing Differential Case And Special Tools
    G02743610Courtesy of FORD MOTOR CO.
  12. Remove the differential case and the special tools.
    13. CAUTION: If reusing original pinion gears, side gears or thrust washers, install in the same locations that they were removed.
    Fig 13: Installing Pinion Gears, Side Gears And Thrust Washers
    G02743611Courtesy of FORD MOTOR CO.
  13. Install the two pinion gears, two side gears and four thrust washers.
    1. Position the side gears and side gear thrust washers.
    2. Rotate the pinion gears and pinion gear thrust washers to the differential pinion shaft hole in the differential case.
      • Apply rear axle lubricant to the pinion gears, side gears and thrust washers.
  14. Install the differential pinion shaft.
    1. Install the differential pinion shaft.
    2. Install the differential pinion shaft lock pin.
    Fig 14: Installing Differential Pinion Shaft Lock Pin
    G02743612Courtesy of FORD MOTOR CO.
    15. WARNING: Gear teeth have sharp edges. Use care when handling the drive pinion. Failure to follow these instructions may result in personal injury.
    Fig 15: Installing Ring Gear
    G02743613Courtesy of FORD MOTOR CO.
  15. Install the ring gear.
    1. Position the ring gear.
    2. Install new ring gear bolts in an alternately and evenly pattern.
  16. Using the special tools, install the differential case into the axle housing.
    • Install the special tools on the same ends of the differential case as they were previously installed.
    • Locate the tip of the dial indicator on the flat surface of one of the ring gear bolts.
    Fig 16: Setting Up Dial Indicator On Flat Surface Of One Of Ring Gear Bolts
    G02743614Courtesy of FORD MOTOR CO.
    17. NOTE: Repeat this step until a same reading is obtained twice.
    Fig 17: Measuring Differential Case Total End Play
    G02743615Courtesy of FORD MOTOR CO.
  17. Seat the differential case away from the drive pinion then push the differential case toward the drive pinion while measuring and recording the differential case total end play.
  18. Remove the differential case and special tools.
    Fig 18: Removing Differential Case And Special Tools
    G02743616Courtesy of FORD MOTOR CO.
  19. Calculate for the differential case bearing shims as follows:
    DIFFERENTIAL CASE BEARING SHIMS

    Differential case shim selection Value
    Total differential case end play without ring gear installed  
    Total differential case end play with ring gear installed  
    Step One minus Step Two  
    Total shims necessary for the ring gear side of differential case (Step Two plus 0.076 mm [ 0.003 in])  
    Total shims necessary for the opposite side of the ring gear of differential case (Step Three plus 0.25 mm [0.01 in])  
    DIFFERENTIAL CASE BEARING SHIMS SPECIFICATION EXAMPLE

    Differential case shim selection Value
    Total differential case end play without ring gear installed 1.066 mm (0.042 in)
    Total differential case end play with ring gear installed 0.660 mm (0.026 in)
    Step One minus Step Two 0.406 mm (0.016 in)
    Total shims necessary for the ring gear side of differential case (Step two plus 0.076 mm [0.003 in]) 0.736 mm (0.029 in)
    Total shims necessary for the opposite side of the ring gear of differential case (Step three plus 0.25 mm [0.01 in]) 0.660 mm (0.026in)
    20. NOTE: If the special tools do not measure 18.136 mm (0.714 in) + or -0.025 mm (0.001 in), the numbers in Step One will be overstated by the difference measured on each special tool. The number in Step Two will be overstated by the difference measured on special tool. Adjustments to the shim pack will have to be made in order to prevent bearing pre-loads from becoming excessive.
  20. Measure the width of the special tools used on the ends of the differential case and select the differential case bearing shims as necessary.
    21. NOTE: RH shown; LH similar.
    Fig 19: Installing Differential Case Bearings And Correct Shims
    G02743617Courtesy of FORD MOTOR CO.
  21. Using the special tools, install the differential case bearings and correct shims.
    22. CAUTION: Overspreading can damage the axle housing.
    Fig 20: Installing Differential Case
    G02743618Courtesy of FORD MOTOR CO.
  22. Using the special tools, install the differential case.
    1. Spread the axle housing.
    2. Install the differential case.
  23. Remove the special tools.
    Fig 21: Installing Special Tools
    G02743619Courtesy of FORD MOTOR CO.
  24. Install the bearing caps.
    1. Position the bearing caps in the position they were removed.
    2. Install the bolts.
    Fig 22: Installing Bearing Caps & Bolts
    G02743620Courtesy of FORD MOTOR CO.
    25. NOTE: The ring gear backlash should be measured at three equally spaced points on the ring gear. If the reading is high, the ring gear must be moved closer to the drive pinion by moving shims to the ring gear side from the opposite side. If the readings are low, the ring gear must be moved away from the drive pinion by moving shims from the ring gear side to the opposite side.
    Fig 23: Measuring Ring Gear Backlash
    G02743621Courtesy of FORD MOTOR CO.
  25. Measure and adjust the ring gear backlash as necessary.
  26. Position the axle assembly with the drive pinion stem facing upward.
    27. NOTE: The total turning torque should be the drive pinion rotational torque plus 0.68 -1.13 Nm (6-10 in-lb). If the total turning torque is too high, subtract an equal amount of shims from each side of the differential case. If the total turning torque is too low, add an equal amount of shims to both sides of the differential case.
    Fig 24: Measuring Total Turning Torque To Rotate Drive Pinion
    G02743622Courtesy of FORD MOTOR CO.
  27. Measure and record the total turning torque to rotate the drive pinion and adjust as necessary.
    28. CAUTION: Lubricate the needle bearings with premium long-life grease prior to installation.
    NOTE: RH shown; LH similar.
    Fig 25: Installing Halfshaft Bearings
    G02743623Courtesy of FORD MOTOR CO.
  28. Using the special tools, install the halfshaft bearings.
  29. Using the special tools, install the halfshaft seals.
    Fig 26: Installing Halfshaft Seals
    G02743624Courtesy of FORD MOTOR CO.
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