Differential Shim Selection

SPECIAL TOOLS

Shim Gauge, Differential/Transfer Gear Bearing 307-591 (includes 307-591/1, 307-591/2 and 307-591/3)

1. Install the differential and transfer shaft bearing cups on the bearings.
   Fig 1: Installing Differential And Transfer Shaft Bearing Cups

   Courtesy of FORD MOTOR CO.
2. Install the Differential/Transfer Gear Bearing Shim Gauge 307-591 (307-591/1 and 307-591/2) on the differential and transfer shaft bearing cups.
   Fig 2: Installing Differential/Transfer Gear Bearing Shim Gauge On Differential And Transfer Shaft Bearing Cups

   Courtesy of FORD MOTOR CO.
3. Install the Differential/Transfer Gear Bearing Shim Gauge 307-591/3 (studs) in the transaxle case to align the torque converter housing.
   Fig 3: Installing Differential/Transfer Gear Bearing Shim Gauge In Transaxle Case To Align Torque Converter Housing

   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 the Differential/Transfer Gear Bearing Shim Gauge 307-591/3 (4 spacers) or the preload measurement may be inaccurate.
Fig 4: Installing Differential/Transfer Gear Bearing Shim Gauge 307-591/3 On Studs
Courtesy of FORD MOTOR CO.
4. Install the Differential/Transfer Gear Bearing Shim Gauge 307-591/3 (4 spacers) on the studs to space the torque converter housing from the transaxle case.
5. Place the torque converter housing on the Differential/Transfer Gear Bearing Shim Gauge 307-591/3 (4 spacers).
   Fig 5: Location of Torque Converter Housing

   Courtesy of FORD MOTOR CO.
6. Install the Differential/Transfer Gear Bearing Shim Gauge 307-591/3 (remaining 4 spacers, bolts and washers).
   • Tighten to 24 Nm (18 lb-ft).
   Fig 6: Identifying Differential/Transfer Gear Bearing Shim Gauge 307-591/3

   Courtesy of FORD MOTOR CO.
7. Install the Differential/Transfer Gear Bearing Shim Gauge 307-591/3 (4 nuts and washers) on the studs.
   • Tighten to 24 Nm (18 lb-ft).
   Fig 7: Identifying Differential/Transfer Gear Bearing Shim Gauge 307-591/3 On Studs

   Courtesy of FORD MOTOR CO.
8. 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.
9. Using a feeler gauge, measure and record the smallest and largest preload gap on the Differential/Transfer Gear Bearing Shim Gauge 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 Specifications  for the differential bearing preload shim part number.
   Fig 9: Checking Thickness Of Differential Bearing Preload Shim Using Feeler Gauge-On Differential Assembly

   Courtesy of FORD MOTOR CO.
10. Using a feeler gauge, measure and record the smallest and largest preload gap on Differential/Transfer Gear Bearing Shim Gauge 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 Specifications  for the transfer gear bearing preload shim part number.
    Fig 10: Checking Thickness Of Differential Bearing Preload Shim Using Feeler Gauge-On Transfer Shaft Assembly

    Courtesy of FORD MOTOR CO.
11. Remove the torque converter housing and the Differential/Transfer Gear Bearing Shim Gauge 307-591/3 (4 nuts, bolts and spacers and 8 washers) from the transaxle case.
    Fig 11: Location of Torque Converter Housing

    Courtesy of FORD MOTOR CO.
12. Remove the Differential/Transfer Gear Bearing Shim Gauge 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.
13. Remove the Differential/Transfer Gear Bearing Shim Gauge 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.
14. Remove the Differential/Transfer Gear Bearing Shim Gauge 307-591/1 and 307-591/2 from the differential and transfer shaft assemblies.
    Fig 14: Removing Differential/Transfer Gear Bearing Shim Gauge 307-591 (307-591/1 And 307-591/2)

    Courtesy of FORD MOTOR CO.
15. Remove the differential and transfer shaft bearing cups.
    Fig 15: Removing Differential And Transfer Shaft Bearing Cups

    Courtesy of FORD MOTOR CO.
16. Assemble the torque converter housing. For additional information, refer to Torque Converter Housing  .