General Procedure

Install the differential and transfer shaft bearing cups on the bearings.

Fig 1: Removing/Installing Differential And Transfer Shaft Bearing Cups
Courtesy of FORD MOTOR CO.
Install 307-591 on the differential and transfer shaft bearing cups.

Fig 2: Identifying Differential/Transfer Gear Bearing Shim Gauge 307-591 (307-591/1 And 307-591/2)
Courtesy of FORD MOTOR CO.
Install 307-591 /3 (studs) in the transaxle case to align the torque converter housing.

Fig 3: Installing 307-591 /3 (Studs) In Transaxle Case
Courtesy of FORD MOTOR CO.

NOTE: Make sure that the silicone has been cleaned off the machined surface of the transaxle case and the torque converter housing before installing 307-591 /3 (4 spacers) or the preload measurement may be inaccurate.

Fig 4: Installing 307-591 /3 (4 Spacers) On Studs

Courtesy of FORD MOTOR CO.

Install 307-591 /3 (4 spacers) on the studs to space the torque converter housing from the transaxle case.
Place the torque converter housing on 307-591 /3 (4 spacers).

Fig 5: Locating Torque Converter Housing
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Install 307-591 /3 (remaining 4 spacers, bolts and washers).
Tighten to 24 Nm (18 lb-ft).

Fig 6: Identifying 307-591 /3
Courtesy of FORD MOTOR CO.
Install 307-591 /3 (4 nuts and washers) on the studs.

Fig 7: Identifying Differential/Transfer Gear Bearing Shim Gauge 307-591/3
Courtesy of FORD MOTOR CO.
Rotate the transfer shaft and the differential several times to seat the bearings.

Fig 8: Rotating Transfer Shaft And Differential
Courtesy of FORD MOTOR CO.
Using a feeler gauge, measure and record the smallest and largest preload gap on 307-591 /1 placed on the differential assembly. Add the 2 measurements and divide by 2. This is the thickness of the differential bearing preload shim. For additional information, REFER to GENERAL SPECIFICATIONS in this service information for the differential bearing preload shim part number.

Fig 9: Checking Thickness Of Differential Bearing Preload Shim Using Feeler Gauge
Courtesy of FORD MOTOR CO.
Using a feeler gauge, measure and record the smallest and largest preload gap on 307-591 /2 placed on the transfer shaft assembly. Add the 2 measurements and divide by 2. This is the thickness of the transfer shaft bearing preload shim. For additional information, REFER to GENERAL SPECIFICATIONS in this service information for the transfer gear bearing preload shim part number.

Fig 10: Checking Thickness Of Transfer Shaft Bearing Preload Shim
Courtesy of FORD MOTOR CO.
Remove the torque converter housing and 307-591 /3 (4 nuts, bolts and spacers and 8 washers) from the transaxle case.

Fig 11: Locating Torque Converter Housing
Courtesy of FORD MOTOR CO.
Remove 307-591 /3 (4 spacers) from the transaxle case.

Fig 12: Identifying Differential/Transfer Gear Bearing Shim Gauge 307-591/3 (Spacers)
Courtesy of FORD MOTOR CO.
Remove 307-591 /3 (4 studs) from the transaxle case.

Fig 13: Identifying Differential/Transfer Gear Bearing Shim Gauge 307-591/3 (Studs)
Courtesy of FORD MOTOR CO.
Remove 307-591 /1 and 307-591 /2 from the differential and transfer shaft assemblies.

Fig 14: Identifying Differential/Transfer Gear Bearing Shim Gauge 307-591 (307-591/1 And 307-591/2)
Courtesy of FORD MOTOR CO.
Remove the differential and transfer shaft bearing cups.

Fig 15: Removing/Installing Differential And Transfer Shaft Bearing Cups
Courtesy of FORD MOTOR CO.
Assemble the torque converter housing. REFER to TORQUE CONVERTER HOUSING in this service information.