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Axle Assembly: Assembly

WARNING: This page is about a different car, the 2005 Lincoln LS. However, it is still accessible from the selected car via links, so may be relevant.
  1. If removed, install the rear axle housing support insulator. For additional information, refer to REAR AXLE HOUSING SUPPORT INSULATOR  in this article .
    Fig 1: Installing Rear Axle Housing Support Insulator
    G03995341Courtesy of FORD MOTOR CO.
    2. CAUTION: Always install a new differential pinion shaft roll pin.
  2. If disassembled, assemble the differential case as follows:
    1. Install the differential side gears and differential side gear thrust washers.
    2. Install the differential pinion gears and differential pinion gear thrust washers.
    3. Install the differential pinion shaft.
    4. Install the differential pinion shaft roll pin so the top of the roll pin is flush with the differential case.
  3. 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 2: Seating Bearing Cup In Bore
    G03995382Courtesy of FORD MOTOR CO.
  4. Install the differential pinion bearings and special tools as shown.
    Fig 3: Installing Differential Pinion Bearings And Special Tools
    G03995383Courtesy of FORD MOTOR CO.
    5. NOTE: This step duplicates differential pinion bearing preload.
    Fig 4: Checking Differential Pinion Bearing Preload
    G03878601Courtesy of FORD MOTOR CO.
  5. Thread the special tool onto the screw.
    • Tighten to 2.2 Nm (20 lb-in) rotational torque.
    6. CAUTION: Offset the special tool to obtain an accurate reading.
    Fig 5: Seating Differential Pinion Bearings
    G03995385Courtesy of FORD MOTOR CO.
  6. Rotate the special tool several half turns to seat the differential pinion bearings. Position the special tool as shown.
  7. Install the special tool.
    • Position the special tool in the differential housing differential bearing seat.
    Fig 6: Positioning Special Tool In Differential Housing Differential Bearing Seat
    G03995386Courtesy of FORD MOTOR CO.
  8. Install the differential bearing cap, then install the differential bearing cap bolts.
    • Tighten to 105 Nm (77 lb-ft).
    Fig 7: Installing Differential Bearing Cap
    G03995250Courtesy of FORD MOTOR CO.
  9. Use a differential pinion bearing adjustment shim as a gauge for shim selection. Check the differential pinion bearing adjustment shim thickness between the Gauge Block and the Gauge Tube. A slight drag indicates correct differential pinion bearing adjustment shim selection.
    Fig 8: Checking Differential Pinion Bearing Adjustment Shim Thickness Between Gauge Block And Gauge Tube
    G03995388Courtesy of FORD MOTOR CO.
  10. Remove all of the special tools.
    11. CAUTION: Use the same differential pinion bearings and differential pinion bearing adjustment shim from the differential pinion bearing adjustment shim selection procedure for final assembly.
  11. Position the differential pinion bearing adjustment shim and the inner pinion bearing on the differential pinion stem.
  12. Using the special tools and a suitable press, firmly seat the differential pinion bearing adjustment shim and inner pinion bearing on the differential pinion stem.
    Fig 9: Installing Pinion Bearing
    G03884019Courtesy of FORD MOTOR CO.
    13. CAUTION: Make sure the splines on the differential pinion stem are free of burrs. If burrs are evident, remove them using a fine crocus cloth.
    Fig 10: Identifying Drive Pinion Collapsible Spacer
    G03878606Courtesy of FORD MOTOR CO.
  13. Place a new drive pinion collapsible spacer on the differential pinion stem against the differential pinion stem shoulder.
  14. Install the differential pinion gear with the drive pinion collapsible spacer in the differential housing.
  15. Install the outer pinion bearing and rear pinion oil seal slinger.
    16. CAUTION: Installation without the correct tool can result in early rear pinion oil seal failure.
    CAUTION: If the rear pinion oil seal becomes misaligned during installation, remove it and install a new one.
    NOTE: Coat the rear pinion oil seal lips with grease.
    Fig 11: Installing Rear Pinion Oil Seal
    G03995391Courtesy of FORD MOTOR CO.
  16. Using the special tool, install the new rear pinion oil seal.
    17. NOTE: Disregard the index marks if installing a new rear axle pinion flange.
    Fig 12: Positioning Rear Axle Pinion Flange
    G03995207Courtesy of FORD MOTOR CO.
  17. Position the rear axle pinion flange.
    • Lubricate the rear axle pinion flange splines with grease.
    • Position the rear axle pinion flange.
  18. Using the special tools, install the rear axle pinion flange.
    Fig 13: Installing Rear Axle Pinion Flange
    G03995207Courtesy of FORD MOTOR CO.
    19. CAUTION: Do not, under any circumstance, loosen the differential drive pinion nut to reduce differential pinion bearing preload. If it is necessary to reduce differential pinion bearing preload, install a new drive pinion collapsible spacer and differential drive pinion nut.
    CAUTION: Remove the special tool while taking differential pinion bearing preload readings with the Nm ( lb-in) torque wrench.
    Fig 14: Tightening Differential Drive Pinion Nut
    G03995202Courtesy of FORD MOTOR CO.
  19. Use the special tool to hold the rear axle pinion flange while tightening the differential drive pinion nut.
    • Rotate the differential pinion gear occasionally to make sure the differential pinion bearings seat correctly. Take frequent differential pinion bearing preload readings by rotating the differential pinion gear with a Nm (lb-in) torque wrench.
  20. Tighten the differential drive pinion nut to set the differential pinion bearing preload.
    Fig 15: Checking Differential Pinion Bearing Preload
    G03995201Courtesy of FORD MOTOR CO.
  21. Install the special tools on the differential case.
    Fig 16: Installing Special Tools On Differential Case
    G03995396Courtesy of FORD MOTOR CO.
  22. Position the special tool on the differential case in the differential housing.
    Fig 17: Positioning Special Tool On Differential Case In Differential Housing
    G03995397Courtesy of FORD MOTOR CO.
  23. Install a unique set-up selective snap ring with a thickness of 2.54 mm (0.100 in).
    • The selective snap ring is available from the Ford dealer parts department.
    Fig 18: Installing Snap Ring
    G03995260Courtesy of FORD MOTOR CO.
    24. NOTE: Repeat this step until obtaining a consistent reading.
    Fig 19: Determining Shim Thickness
    G03995399Courtesy of FORD MOTOR CO.
  24. 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

    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
  25. Remove the Dial Indicator and the differential case from the differential housing.
  26. Install the differential ring gear.
    1. Place the differential ring gear on the differential case.
    2. Hand start 3 differential ring gear 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 20: Pressing Differential Ring Gear
    G03995400Courtesy of FORD MOTOR CO.
  27. Install the remaining differential ring gear bolts.
    • Tighten to 120 Nm (89 lb-ft).
    Fig 21: Identifying Differential Ring Gear Bolts
    G03995241Courtesy of FORD MOTOR CO.
  28. Place the differential case with the special tool into the differential housing.
    Fig 22: Placing Differential Case With Special Tool Into Differential Housing
    G03995402Courtesy of FORD MOTOR CO.
  29. Install the special tool.
    Fig 23: Installing Special Tool
    G03995403Courtesy of FORD MOTOR CO.
  30. 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 24: Measuring End Play
    G03995404Courtesy of FORD MOTOR CO.
  31. Remove the differential case from the differential housing.
    Fig 25: Removing Differential Case From Differential Housing
    G03995267Courtesy of FORD MOTOR CO.
  32. Remove the differential ring gear bolts. Apply Stud and Bearing Mount to the differential ring gear bolt threads, and reinstall the differential ring gear bolts.
    • Tighten to 120 Nm (89 lb-ft).
    Fig 26: Identifying Differential Ring Gear Bolts
    G03995241Courtesy of FORD MOTOR CO.
  33. Using a suitable press, press the differential bearings on the differential case.
    Fig 27: Pressing Differential Bearings On Differential Case
    G03995268Courtesy of FORD MOTOR CO.
  34. Place the differential case and differential bearing cups in the differential case.
    Fig 28: Placing Differential Case And Differential Bearing Cups In Differential Case
    G03995269Courtesy of FORD MOTOR CO.
    35. NOTE: Select the correct size selective snap ring using the differential bearing shim selection chart.
    NOTE: To determine the thickness of the selective 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 selective snap ring required.
    Fig 29: Installing Snap Ring
    G03995260Courtesy of FORD MOTOR CO.
  35. Place the selective snap ring in the differential housing.
    36. NOTE: Select the correct size selective bearing shim using the differential bearing shim selection chart.
    NOTE: To determine the thickness of the differential 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 differential bearing shim required.
    Fig 30: Positioning Differential Bearing Shim
    G03995271Courtesy of FORD MOTOR CO.
  36. Position the differential bearing shim indicated by the differential bearing shim selection chart.
  37. Using the special tools, seat the differential bearing shim in the differential housing.
    Fig 31: Seating Differential Bearing Shim In Differential Housing
    G03995411Courtesy of FORD MOTOR CO.
  38. Install the differential bearing cap, then the differential bearing cap bolts in the original location.
    • Tighten to 105 Nm (77 lb-ft).
    Fig 32: Identifying Differential Bearing Cap Bolt
    G03995240Courtesy of FORD MOTOR CO.
  39. Lubricate the lips of the halfshaft housing seal with grease.
  40. Using the special tools, install the halfshaft housing seal.
    Fig 33: Installing Halfshaft Housing Seal
    G03995196Courtesy of FORD MOTOR CO.
  41. Using the special tools, measure the differential ring gear backlash at 4 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 differential 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 axle assembly.
      • To correct for a high or low backlash, proceed as follows.
    Fig 34: Measuring Differential Ring Gear Backlash
    G03995414Courtesy of FORD MOTOR CO.
  42. 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

    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 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
    2GRN 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
    2BLU 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
    2BLK 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 4.21 0.1657
    5 PINK/1 BLK 4.23 0.1665
    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 6.1722-6.1849 0.2430-0.2435
    1 - RED 6.1214-6.1341 0.2410-0.2415
  43. Remove the differential assembly from the special tool.
    Fig 35: Identifying Differential Assembly & Special Tool
    G03995368Courtesy of FORD MOTOR CO.
    44. CAUTION: The differential housing cover must be installed within 15 minutes of application of the Silicone Gasket and Sealant.
    CAUTION: Allow the Silicone Gasket and Sealant to cure for one hour before filling the axle with lubricant.
  44. Apply a continuous bead of Silicone Gasket and Sealant to the differential housing cover mounting surface, then install the differential housing cover.
  45. Install the rear axle assembly. For additional information, refer to AXLE ASSEMBLY  in this article .
  46. Fill the axle.
    • Use Rear Axle Lubricant to 3-5 mm (1/8-3/16 in) from the bottom of the filler hole.
    • Tighten to 34 Nm (25 lb-ft).
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