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Rear Axle Assembly: Material

WARNING: This page is about a different car, the 2004 Lincoln LS. However, it is still accessible from the selected car via links, so may be relevant.
MATERIAL SPECIFICATION

Item Specification
Premium Long Life Grease XG-1-C ESA-M1C75-B
SAE 75W-140 Synthetic Rear Axle Lubricant XY-75W140-QL WSL-M2C192-A
Stud and Bearing Mount E0AZ-19554-BA WSK-M2G349-A1
  1. With the vehicle in NEUTRAL, position on a hoist.
  2. Remove the rear axle assembly. For additional information, refer to REAR AXLE ASSEMBLY .
  3. Remove the components in the order indicated in the following illustration and table.
  4. To assemble, reverse the disassembly procedure.
    Fig 1: Exploded View Of Rear Axle Assembly Components (1 Of 2)
    G03200052Courtesy of FORD MOTOR CO.
    Fig 2: Exploded View Of Rear Axle Assembly Components (2 Of 2)
    G03200053Courtesy of FORD MOTOR CO.
  5. Fill the axle with the specified quantity of the specified lubricant.

Item 3: Differential Housing Cover Disassembly Note 

  1. After removal of the rear housing cover, mount the differential assembly in the special tool.
    Fig 3: Mounting Differential Assembly In Special Tool
    G03200054Courtesy of FORD MOTOR CO.

Item 4: Pinion Nut Disassembly Note 

  1. Install a N.m (inch-pound) torque wrench on the nut and record the torque necessary to maintain rotation of the drive pinion gear through several revolutions
    Fig 4: Installing N.m (Inch-Pound) Torque Wrench On Nut
    G03200055Courtesy of FORD MOTOR CO.
  2. Index-mark the rear axle pinion flange to the drive pinion stem.
    Fig 5: Marking Rear Axle Pinion Flange To Drive Pinion Stem
    G03200056Courtesy of FORD MOTOR CO.
    3. CAUTION: After removing the nut, discard it. Use a new nut for installation.
    Fig 6: Removing Rear Axle Pinion Flange Nut
    G03200057Courtesy of FORD MOTOR CO.
  3. Use the special tool to hold the rear axle pinion flange while removing the nut.

Item 5: Rear Axle Pinion Flange Disassembly Note 

  1. Using the special tool, remove the rear axle pinion flange.
    Fig 7: Removing Rear Axle Pinion Flange
    G03200058Courtesy of FORD MOTOR CO.

Item 7: Rear Pinion Oil Seal Disassembly Note 

  1. Use a screwdriver to force up the metal flange of the rear pinion oil seal. Install gripping pliers and strike with a hammer to remove the rear pinion oil seal.
    Fig 8: Removing Rear Pinion Oil Seal
    G03200059Courtesy of FORD MOTOR CO.

Item 12: Halfshaft Housing Seal Disassembly Note 

  1. Force up the metal flange on the halfshaft seal.
    Fig 9: Forcing Up Metal Flange On Halfshaft Seal
    G03200060Courtesy of FORD MOTOR CO.
  2. Install gripping pliers and strike with a hammer to remove the seal from the housing.
    Fig 10: Removing Seal From Housing
    G03200061Courtesy of FORD MOTOR CO.

Item 22: Inner Pinion Bearing Disassembly Note 

  1. Using the special tool and a press, remove the pinion bearing.
    1. Position the special tool under the pinion bearing.
    2. Using a press, remove the pinion bearing.
    Fig 11: Removing Pinion Bearing
    G03200062Courtesy of FORD MOTOR CO.

Item 24: Inner Pinion Bearing Cup Disassembly Note 

  1. Using the drift punch and a hammer, remove the inner pinion bearing cup.

Item 25: Outer Pinion Bearing Cup Disassembly Note 

  1. Using the commercially available drift punch and a hammer, remove the outer pinion bearing cup.
    Fig 12: Removing Outer Pinion Bearing Cup
    G03200063Courtesy of FORD MOTOR CO.

Item 26: Differential Bearing Disassembly Note 

  1. Using the special tools, remove the differential bearing.
    • Repeat for the other side.
    Fig 13: Removing Differential Bearing
    G03200064Courtesy of FORD MOTOR CO.

Item 27: Differential Pinion Shaft Roll Pin Disassembly Note 

  1. Using a drift punch and a hammer, drive the roll pin into the pinion shaft until bottomed. The pinion shaft roll pin will remain in the shaft when the pinion shaft is removed from the case. Drive the roll pin from the pinion shaft after the shaft is removed from the case. Discard the roll pin.

Item 33: Axle Isolator Bushing Disassembly Note 

  1. Using the special tools, remove the rear axle isolator bushing.
    Fig 14: Removing Rear Axle Isolator Bushing
    G03200065Courtesy of FORD MOTOR CO.

Item 33: Axle Isolator Bushing Assembly Note 

  1. Align the notches in the bushing at 45° from the fore and aft position.
    Fig 15: Aligning Notches In Bushing At 45° From Fore And Aft Position
    G03200066Courtesy of FORD MOTOR CO.
  2. Using the special tools, install the rear axle isolator bushing.
    Fig 16: Installing Rear Axle Isolator Bushing
    G03200067Courtesy of FORD MOTOR CO.

Item 27: Differential Pinion Shaft Roll Pin Assembly Note 

    CAUTION: Always use a new roll pin.
  1. Install the differential shaft roll pin so the top of the roll pin is flush with the differential case.

Item 24 and 25: Outer and Inner Pinion Bearing Cup Assembly Note 

  1. Coat the new differential drive pinion bearing cup(s) with lubricant.
  2. Using the special tool, install the differential drive pinion bearing cup(s).
    • Position the bearing cup(s) on the special tool.
    • Position the special tool and the bearing cup(s) in the differential housing.
    • Tighten the special tool to fully seat the bearing cup(s) in the bore(s).
    Fig 17: Tightening Special Tool To Fully Seat Bearing Cup(s) In Bore(s)
    G03200068Courtesy of FORD MOTOR CO.

Item 23: Differential Pinion Bearing Adjustment Shim Assembly Note 

    NOTE: Apply a light film of lubricant on the front and rear pinion bearings.
    Fig 18: Installing Pinion Bearings And Special Tools
    G03200069Courtesy of FORD MOTOR CO.
  1. Install the pinion bearings and special tools as shown.
    2. NOTE: This step duplicates pinion bearing preload.
    Fig 19: Threading Special Tool Onto Screw
    G03200070Courtesy of FORD MOTOR CO.
  2. Thread the special tool onto the screw and tighten to the specification shown.
    3. CAUTION: Offset the special tool to obtain an accurate reading.
    Fig 20: Rotating Special Tool Several Half Turns To Seat Pinion Bearings
    G03200071Courtesy of FORD MOTOR CO.
  3. Rotate the special tool several half turns to seat the pinion bearings. Position the special tool as shown.
  4. Install the special tool.
    • Position the special tool in the differential housing differential bearing seat.
      Fig 21: Installing Special Tool In Differential Housing Differential Bearing Seat
      G03200072Courtesy of FORD MOTOR CO.
  5. Install the differential bearing cap.
    • Seat the special tool in the housing.
    • Position the bearing cap.
    • Torque the cap to specification.
    Fig 22: Installing Differential Bearing Cap
    G03200073Courtesy of FORD MOTOR CO.
  6. Use a drive pinion bearing adjustment shim as a gauge for shim selection. Check the drive pinion bearing adjustment shim thickness between the Gauge Block and the Gauge Tube. A slight drag indicates correct shim selection.
    Fig 23: Checking Drive Pinion Bearing Adjustment Shim Thickness
    G03200074Courtesy of FORD MOTOR CO.
  7. Remove all of the special tools.
    8. CAUTION: Use the same pinion bearings and drive pinion bearing adjustment shim from the drive pinion bearing adjustment shim selection procedure for final assembly.
  8. Position the drive pinion bearing adjustment shim and the pinion bearing on the drive pinion gear stem.

Item 22: Inner Pinion Bearing Assembly Note 

  1. Using the special tools and a suitable press, firmly seat the drive pinion bearing adjustment shim and pinion bearing on the drive pinion gear stem.
    Fig 24: Installing Inner Pinion Bearing
    G03200075Courtesy of FORD MOTOR CO.

Item 13, Item 14, Item 18 and Item 26: Selective Snap Ring, Differential Bearing Shim, Differential Case and Differential Bearing Assembly Note 

  1. Install the special tools on the differential case.
    Fig 25: Installing Special Tools On Differential Case
    G03200076Courtesy of FORD MOTOR CO.
  2. Place the differential case with the special tool in the differential housing.
    Fig 26: Placing Differential Case With Special Tool In Differential Housing
    G03200077Courtesy of FORD MOTOR CO.
  3. Position the special tool on the differential case in the differential housing.
    Fig 27: Positioning Special Tool On Differential Case In Differential Housing
    G03200078Courtesy of FORD MOTOR CO.
  4. Install a unique set-up selective snap ring with a thickness of 0.100 inches.
    Fig 28: Installing Set-Up Selective Snap Ring With Thickness Of 0.100 inches
    G03200079Courtesy of FORD MOTOR CO.
  5. Position the special tool.
    Fig 29: Positioning Special Tool
    G03200080Courtesy of FORD MOTOR CO.
    6. NOTE: Repeat this step until obtaining a consistent reading.
  6. Measure the total end play.
    • Attach the special tools and position the indicator tip on the machined surface of the differential case flange.
    • Move the differential case to the left and the right (as far as possible).
    • Record the reading in Line A.

    Differential Bearing Shim Selection Chart 

    DIFFERENTIAL BEARING SHIM SELECTION CHART

    8.0 Inch Lightweight Axle Example Actual
    Line A Total end play without ring gear 0.230  
    Line B Total end play with ring gear 0.193  
    Line C Subtract Line B from Line A 0.037  
    Line D Initial backlash clearance 0.016 0.016
    Line E Set-up snap ring thickness 0.100 0.100
    Line F Left Master Bearing compensation 0.100 0.100
    Line G Carrier bearing preload 0.012 0.012

    To determine the snap ring thickness, add lines C, D and E (Example: 0.037 + 0.016 + 0.100 = 0.153 snap ring thickness).

    To determine the bearing shim thickness, add lines A, F and G. Subtract line C and D from the sum. Example:

    • 0.230 + 0.100 + 0.012 = 0.342
    • 0.342 - 0.037 - 0.016 = 0.289 bearing shim thickness
      • Fig 30: Measuring Total End Play
      G03200081Courtesy of FORD MOTOR CO.

  7. Remove the Dial Indicator and the differential case from the differential housing.
  8. Install the differential ring gear.
    1. Place the differential ring gear on the differential case.
    2. Hand start three bolts to align the holes in the differential ring gear and the differential case.
    3. Place the differential case and differential ring gear onto the press bed blocks with the differential ring gear teeth facing downward.
    4. Press the differential ring gear into place.
    Fig 31: Installing Differential Ring Gear
    G03200082Courtesy of FORD MOTOR CO.
  9. Install the remaining bolts.
    Fig 32: Tightening Differential Ring Gear Bolts
    G03200083Courtesy of FORD MOTOR CO.
  10. Place the differential case with the special tool into the differential housing.
    Fig 33: Placing Differential Case With Special Tool Into Differential Housing
    G03200084Courtesy of FORD MOTOR CO.
  11. Install the special tool.
    Fig 34: Installing Special Tool
    G03200085Courtesy of FORD MOTOR CO.
  12. Measure the end play.
    • Attach the special tool and position the indicator tip on the machined surface of the differential case flange.
    • Rock the differential ring gear to allow full mesh with the drive pinion gear.
    • With the gears in full mesh, set the special tool to zero.
    • Move the differential case as far as possible to the left and note the reading.
    • Record the reading on the differential bearing shim selection procedure Line B.
      • Remove the special tool.
      • Fig 35: Measuring End Play
      G03200086Courtesy of FORD MOTOR CO.
  13. Remove the differential case from the differential housing.
    Fig 36: Removing Differential Case From Differential Housing
    G03200087Courtesy of FORD MOTOR CO.
  14. Remove the bolts. Apply stud and bearing mount to the bolt threads, and reinstall the bolts.
    Fig 37: Removing Differential Case Bolts
    G03200088Courtesy of FORD MOTOR CO.
  15. Press the left and right differential bearing on the differential case.
    Fig 38: Pressing Left And Right Differential Bearing On Differential Case
    G03200089Courtesy of FORD MOTOR CO.
  16. Place the differential case and bearing cups in the differential case.
    Fig 39: Placing Differential Case And Bearing Cups In Differential Case
    G03200090Courtesy of FORD MOTOR CO.
    17. NOTE: Select the correct size selective snap ring using the differential bearing shim selection chart.
    NOTE: To determine the thickness of the snap ring to be used, subtract Line B from Line A. Add Lines D and E to the difference. This is the thickness of the snap ring required.
    Fig 40: Placing Selective Snap Ring In Differential Housing
    G03200091Courtesy of FORD MOTOR CO.
  17. Place the selective snap ring in the differential housing.
    18. NOTE: Select the correct size selective bearing shim using the differential bearing shim selection chart.
    NOTE: To determine the thickness of the bearing shim to be used, add Lines A, F and G. Subtract Lines C and D from the sum. This is the thickness of the bearing shim required.
    Fig 41: Positioning Differential Bearing Shim
    G03200092Courtesy of FORD MOTOR CO.
  18. Position the differential bearing shim indicated by the bearing shim selection chart.
  19. Using the special tools, seat the differential bearing shim in the differential housing.
    Fig 42: Seating Differential Bearing Shim In Differential Housing
    G03200093Courtesy of FORD MOTOR CO.
  20. Install the differential bearing cap in the original location and tighten the bolts.
    Fig 43: Tightening Differential Bearing Cap
    G03200094Courtesy of FORD MOTOR CO.
  21. Using the special tools, measure the differential ring gear backlash at four equally spaced points.
    • Attach the special tool.
    • Position the special tool tip centrally on a drive tooth.
    • Zero the indicator.
    • Turn the differential ring gear without turning the drive pinion gear. Record the indicator reading. The allowable backlash is 0.127 mm (0.005 in) to 0.228 mm (0.009 in) and must not vary more than 0.076 mm (0.003 in) between points measured. A backlash variation of more than 0.076 mm (0.003 in) between points checked indicates gear/case runout.
      • If backlash is within specifications, install the differential assembly.
      • To correct for a high or low backlash, proceed as follows.
    Fig 44: Measuring Differential Ring Gear Backlash
    G03200095Courtesy of FORD MOTOR CO.
  22. To correct for high or low backlash, increase or decrease the thickness of the differential bearing shim and decrease or increase the thickness of the selective snap ring by the same amount. Refer to the following tables when adjusting the backlash. When the backlash is within specifications, install the differential assembly.
    BACKLASH CHANGE REQUIRED AND THICKNESS CHANGE REQUIRED

    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
    0.381    		 0.014
    0.015    		 0.457
    0.508    		 0.018
    0.020

    Differential Snap Ring Size Chart - 13277 - 

    DIFFERENTIAL SNAP RING SIZE CHART - 13277

    Numbers of Stripes and Color Code Dimension A
    mm in
    1 YEL 3.15 0.1240
    2 YEL 3.17 0.1248
    3 YEL 3.19 0.1256
    4 YEL 3.21 0.1264
    5 YEL 3.23 0.1272
    1 WH 3.25 0.1280
    2 WH 3.27 0.1287
    3 WH 3.29 0.1295
    4 WH 3.31 0.1303
    5 WH 3.33 0.1311
    1 GRN 3.35 0.1319
    2 GRN 3.37 0.1327
    3 GRN 3.39 0.1335
    4 GRN 3.41 0.1343
    5 GRN 3.43 0.1350
    1 PINK 3.45 0.1358
    2 PINK 3.47 0.1366
    3 PINK 3.49 0.1374
    4 PINK 3.51 0.1382
    5 PINK 3.53 0.1390
    1 BLU 3.55 0.1398
    2 BLU 3.57 0.1406
    3 BLU 3.59 0.1413
    4 BLU 3.61 0.1421
    5 BLU 3.63 0.1429
    1 BLK 3.65 0.1437
    2 BLK 3.67 0.1445
    3 BLK 3.69 0.1453
    4 BLK 3.71 0.1461
    5 BLK 3.73 0.1469
    1 BROWN 3.75 0.1476
    2 BROWN 3.77 0.1484
    3 BROWN 3.79 0.1492
    4 BROWN 3.81 0.1500
    5 BROWN 3.83 0.1508
    1 YEL/1 BLK 3.85 0.1516
    2 YEL/1 BLK 3.87 0.1524
    3 YEL/1 BLK 3.89 0.1531
    4 YEL/1 BLK 3.91 0.1539
    5 YEL/1 BLK 3.93 0.1547
    1 WH/1 BLK 3.95 0.1555
    2 WH/1 BLK 3.97 0.1563
    3 WH/1 BLK 3.99 0.1571
    4 WH/1 BLK 4.01 0.1579
    5 WH/1 BLK 4.03 0.1587
    1 GRN/1 BLK 4.05 0.1594
    2 GRN/1 BLK 4.07 0.1602
    3 GRN/1 BLK 4.09 0.1610
    4 GRN/1 BLK 4.11 0.1618
    5 GRN/1 BLK 4.13 0.1626
    1 PINK/1 BLK 4.15 0.1634
    2 PINK/1 BLK 4.17 0.1642
    3 PINK/1 BLK 4.19 0.1650
    4 PINK/1 BLK
    5 PINK/1 BLK    		 4.21
    4.23    		 0.1657
    0.1665

    Differential Shim Size Chart - 4067 - 

    DIFFERENTIAL SHIM SIZE CHART - 4067

    Numbers of Stripes and Color Code Dimension A
    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 7.493- 7.505 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-PINK 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- 7.0485 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 1-RED 6.1722- 6.1849 6.1214- 6.1341 0.2430-0.2435 0.2410-0.2415

Item 12: Halfshaft Housing Seal Assembly Note 

    NOTE: Lubricate the lips of the seal with axle lubricant.
    Fig 45: Installing Halfshaft Housing Seal
    G03200096Courtesy of FORD MOTOR CO.
  1. Using the special tools, install the halfshaft housing seal.

Item 10: Drive Pinion Collapsible Spacer Assembly Note 

    CAUTION: Make sure the splines on the drive pinion gear stem are free of burrs. If burrs are evident, remove them using a fine crocus cloth.
    Fig 46: Installing Drive Pinion Collapsible Spacer
    G03200097Courtesy of FORD MOTOR CO.
  1. Place a new differential drive pinion collapsible spacer on the drive pinion gear stem against the pinion stem shoulder.
  2. Install the drive pinion gear with the differential drive pinion collapsible spacer in the differential housing.

Item 7: Rear Pinion Oil Seal Assembly Note 

    CAUTION: Installation without the correct tool can result in early seal failure.
    CAUTION: If the seal becomes misaligned during installation, remove it and install a new one.
    NOTE: Coat the rear axle drive pinion seal lips with grease.
    Fig 47: Installing Rear Axle Drive Pinion Seal
    G03200098Courtesy of FORD MOTOR CO.
  1. Using the special tool, install the new rear axle drive pinion seal.

Item 5: Rear Axle Pinion Flange Assembly Note 

    NOTE: Disregard the index marks if installing a new rear axle pinion flange.
    Fig 48: Positioning Rear Axle Pinion Flange
    G03200099Courtesy of FORD MOTOR CO.
  1. Position the rear axle pinion flange.
    • Lubricate the rear axle pinion flange splines.
    • Position the rear axle pinion flange.
  2. Using the special tools, install the rear axle pinion flange.
    Fig 49: Installing Rear Axle Pinion Flange
    G03200100Courtesy of FORD MOTOR CO.

Item 4: Pinion Nut Assembly Note 

    CAUTION: Do not, under any circumstance, loosen the nut to reduce preload. If it is necessary to reduce preload, install a new collapsible spacer and nut.
    CAUTION: Remove the special tool while taking preload readings with the N.m (inch-pound) torque wrench.
    Fig 50: Tightening Pinion Flange Nut
    G03200101Courtesy of FORD MOTOR CO.
  1. Use the special tool to hold the pinion flange while tightening the nut.
    • Rotate the pinion occasionally to make sure the differential pinion bearings seat correctly. Take frequent differential pinion bearing preload readings by rotating the pinion with a N.m (inch-pound) torque wrench.
  2. Tighten the nut to set the preload.
    Fig 51: Tightening Nut To Set Preload
    G03200102Courtesy of FORD MOTOR CO.
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