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Disassembly And Assembly

WARNING: This page is about a different car, the 2004 Mercury Mountaineer and 2004 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.
  1. Position the vehicle on a hoist. For additional information, refer to JACKING & LIFTING .
  2. Remove the rear axle assembly. For additional information, refer to REAR AXLE ASSEMBLY .
  3. Remove the parts in the order indicated in the following illustration and table.
    Fig 1: Exploded View Of Differential Assembly(1 Of 2)
    G03190463Courtesy of FORD MOTOR CO.
    Fig 2: Exploded View Of Differential Assembly(2 Of 2)
    G03190464Courtesy of FORD MOTOR CO.
  4. To assemble, reverse the disassembly procedure.
  5. Fill the axle with the specified quantity of the specified lubricant. For additional information, refer to the SPECIFICATIONS .

Item 2: Rear Axle Pinion Flange Disassembly Note 

  1. Using the special tool, remove the rear axle pinion flange.
    Fig 3: Removing Rear Axle Pinion Flange Using Special Tool
    G03190465Courtesy of FORD MOTOR CO.

Item 4: 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 4: Removing Rear Pinion Oil Seal
    G03190466Courtesy of FORD MOTOR CO.

Item 15: Differential Case Disassembly Note 

    CAUTION: Do not damage the aluminum differential housing while carrying out these procedures.
    Fig 5: Attaching Special Tools
    G03190467Courtesy of FORD MOTOR CO.
  1. Using the special tools, mount the differential housing to a work bench.
    1. Attach the special tools to the differential housing with four bolts that retain the differential housing cover to the differential housing.
    2. Attach the special tools together with two 3/8 inch x 1-1/2 inch bolts.
    2. CAUTION: Do not tighten RH case spreader set screw lower than flush. Axle seal or axle case damage can occur.
    Fig 6: Placing Spreader Pins In Hole Of Housing Spreader Adapters
    G03190468Courtesy of FORD MOTOR CO.
  2. Install the special tool by placing the spreader pins in the hole in the Housing Spreader Adapters.
  3. Assemble the special tools.
    1. Install the special tool.
    2. Attach the special tool and position the tip in the Housing Spreader Adapter hole.
    Fig 7: Attaching Special Tools
    G03190469Courtesy of FORD MOTOR CO.
    4. CAUTION: Overspreading can damage the differential housing.
    NOTE: Tighten and loosen the Differential Carrier Spreader screw to normalize the Housing Spreader Adapters prior to taking the final Dial Indicator reading.
    Fig 8: Spreading Differential Housing To Specification
    G03190470Courtesy of FORD MOTOR CO.
  4. Spread the differential housing to the specification.
    1. Adjust the special tool to zero.
    2. Tighten the screw until the differential housing is spread to the specification.
    3. Remove the special tool.
    5. CAUTION: Mark the position and location of the differential bearing caps as the arrows may not be visible. Always install the differential bearing caps in their identical location and position.
    Fig 9: Removing Differential Bearing Caps
    G03190471Courtesy of FORD MOTOR CO.
  5. Remove the differential bearing caps.
    1. Remove the bolts.
    2. Remove the differential bearing caps.
    6. CAUTION: Use wood blocks to avoid damaging the differential housing.
    Fig 10: Removing Differential Assembly
    G03190472Courtesy of FORD MOTOR CO.
  6. Remove the differential assembly.
    1. Position wood blocks at the top and bottom of the differential case.
    2. Pry the differential assembly and the differential bearing shims out of the differential housing.
    3. Mark the bearing cups and shims for location on installation.
    4. Remove the special tool.

Item 18: Differential Bearing Disassembly Note 

  1. Using the special tools, remove the differential bearing.
    • Repeat for the other side.
    Fig 11: Removing Differential Bearing Using Special Tools
    G03190473Courtesy of FORD MOTOR CO.

Item 21: Differential Pinion Gear Disassembly Note 

  1. Using the special tool and a hammer, remove the differential pinion gear from the differential case.
    Fig 12: Removing Differential Pinion Gear From Differential Case
    G03190474Courtesy 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 13: Removing Pinion Bearing Using Special Tool
    G03190475Courtesy of FORD MOTOR CO.

Item 30: Axle Isolator Bushing Disassembly Note 

  1. Using the special tools, remove the rear axle isolator bushing.
    Fig 14: Removing Rear Axle Isolator Bushing Using Special Tools
    G03190476Courtesy of FORD MOTOR CO.

Item 31 and 32: Inner and Outer Pinion Bearing Cup Disassembly Note 

  1. Using a brass drift and a hammer, remove any damaged differential drive pinion bearing cup from the differential housing. Tap alternately on each side of the cup to prevent it from cocking in the bore.
    Fig 15: Removing Differential Drive Pinion Bearing Cup
    G03190477Courtesy of FORD MOTOR CO.

Item 32 and 31: Outer and Inner Pinion Bearing Cup Assembly Note 

    NOTE: When installing differential drive pinion bearing cups, do not use oil.
  1. Apply a light film of lubricant to the carrier housing bores only. Do not use lubricant on the pinion bearing cups.
  2. Using the special tool, install the differential drive pinion bearing cup(s).
    1. Position the bearing cup(s) on the special tool.
    2. Position the special tool and the bearing cup(s) in the differential housing.
    3. Tighten the special tool to fully seat the bearing cup(s) in the bore(s).
    Fig 16: Installing Differential Drive Pinion Bearing Cup
    G03190478Courtesy of FORD MOTOR CO.

Item 30: Axle Isolator Bushing Assembly Note 

  1. Using the special tools, install the rear axle isolator bushing.
    Fig 17: Installing Rear Axle Isolator Bushing
    G03190479Courtesy of FORD MOTOR CO.

Item 23: Drive Pinion Bearing Adjustment Shim Assembly Note

    NOTE: If installing new inner and outer pinion bearings, install them as received, do not use oil. If the original inner and outer pinion bearings are being installed, coat them with light film of new axle lubricant.
    Fig 18: Installing Pinion Bearings And Special Tools
    G03190480Courtesy of FORD MOTOR CO.
  1. Install the pinion bearings and special tools as shown.
    2. NOTE: This step duplicates pinion bearing preload.
    Fig 19: Tightening Nut
    G03190481Courtesy of FORD MOTOR CO.
  2. Thread the special tool onto the Screw and tighten to the specification shown.
    3. CAUTION: Position the adapter so it does not contact the housing.
    CAUTION: Offset the special tool to obtain an accurate reading.
    Fig 20: Positioning Special Tool
    G03190482Courtesy 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.
    1. Position the special tool on the differential housing differential bearing seat.
    2. Install the differential bearing caps.
    3. Install the bolts.
    Fig 21: Positioning Special Tool On Differential Housing Differential Bearing Seat
    G03190483Courtesy of FORD MOTOR CO.
  5. 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.
    • Notice the plus (+), minus (-), or zero (0) paint marking on the drive pinion stem and adjust the thickness of the new shim. If the marking is plus (+), subtract the number from the gauged shim thickness. If the marking is minus (-), add the number to the gauged shim thickness.
    Fig 22: Checking Drive Pinion Bearing Adjustment Shim
    G03190484Courtesy of FORD MOTOR CO.
  6. Remove all of the special tools.
    7. CAUTION: Use the same pinion bearings and drive pinion bearing adjustment shim from the drive pinion bearing adjustment shim selection procedure for final assembly.
  7. 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 23: Seating Drive Pinion Bearing Using Special Tools
    G03190485Courtesy of FORD MOTOR CO.

Item 18: Differential Bearing and Item 15: Differential Case Assembly Note 

    CAUTION: The master bearings are marked LH and RH. Install them as shown.
    Fig 24: Installing Special Tools On Differential Case
    G03190486Courtesy of FORD MOTOR CO.
  1. Install the special tools on the differential case.
    2. CAUTION: Do not damage the aluminum differential housing while carrying out these procedures.
    Fig 25: Placing Differential Case With Special Tools In Differential Housing
    G03190487Courtesy of FORD MOTOR CO.
  2. Place the differential case with the special tools in the differential housing.
  3. Position the special tool on the outside mounting hole.
    Fig 26: Positioning Special Tool On Outside Mounting Hole
    G03190488Courtesy of FORD MOTOR CO.
    4. NOTE: Repeat this step until obtaining a consistent reading.
    Fig 27: Measuring Total End Play
    G03190489Courtesy of FORD MOTOR CO.
  4. Measure the total end play.
    1. Attach the special tool and position the indicator tip on the machined surface of the differential case flange.
    2. Move the differential case to the left and the right (as far as possible).
    3. Record the reading on the differential bearing shim selection procedure line A.

    Differential Bearing Shim Selection Chart 

    ACTUAL CHART

    8.8-inch Aluminum Axle Example Actual
    Line-A End play without ring gear 0.498  
    Line-B End play with ring gear (ring gear side) -0.245 Minus (-)
    Line-C Subtract Line-B from Line-A, also record on Line C, below 0.253  
    SPECIFICATION

    8.8-inch Aluminum Axle Left Differential Bearing Height Right Differential Bearing Height
    Example Actual Example Actual
    Master bearing height 0.8695 0.8695 0.8695 0.8695
    Line-D Actual bearing height -0.8478 Minus (-) -0.8491 Minus (-)
    Line-E Difference 0.0217   0.0204  
    SPECIFICATION

    8.8-inch Aluminum Axle Left Side 8.8-inch Aluminum Axle Right Side
    Example Actual Example Actual
    Line-B End play Line-E Bearing height 0.2450 +0.0217 + Line-C End play Line-E Bearing height 0.2530 +0.0204 +
    TOTAL Lines B and E Backlash (subtract) 0.2667 -0.0060 -0.006 TOTAL Lines C and E Backlash/preload (add) 0.2734 +0.020 +0.020
    Initial thickness (1) 0.2607   Initial thickness 0.2934  
    Final shim thickness - left 0.261   Final shim thickness - right 0.293  
    (1) Round off initial thickness to the nearest shim thickness as in example for final shim thickness.
  5. Remove the Dial Indicator and the differential case from the differential housing.
    Fig 28: Removing Dial Indicator And Differential Case From Differential Housing
    G03190490Courtesy of FORD MOTOR CO.
  6. 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 29: Installing Differential Ring Gear
    G03190491Courtesy of FORD MOTOR CO.
  7. Install the remaining bolts.
    Fig 30: Installing Remaining Bolts
    G03190492Courtesy of FORD MOTOR CO.
  8. Place the differential case with the special tools into the differential housing.
    Fig 31: Placing Differential Case With Special Tools Into Differential Housing
    G03190493Courtesy of FORD MOTOR CO.
    9. NOTE: The bolts retaining the differential ring gear to the differential case may interfere while carrying out this procedure. If so, remove three to five bolts to provide clearance.
  9. Measure the end play.
    1. Attach the special tool and position the indicator tip on the machined surface of the differential case flange.
    2. Rock the differential ring gear to allow full mesh with the drive pinion gear.
    3. With the gears in full mesh, set the special tool to zero.
    4. Move the differential case as far as possible to the left and note the reading.
    5. Record the reading on the differential bearing shim selection procedure line B.
      • Remove the special tool.
      Fig 32: Measuring End Play
      G03190494Courtesy of FORD MOTOR CO.
  10. Remove the differential case from the differential housing.
    Fig 33: Removing Differential Case From Differential Housing
    G03190495Courtesy of FORD MOTOR CO.
  11. Remove the bolts. Apply stud and bearing mount to the bolt threads, and reinstall the bolts.
    Fig 34: Removing Ring Gear Bolts
    G03190496Courtesy of FORD MOTOR CO.
    12. NOTE: Measure the stand height of both differential bearings prior to installation.
    NOTE: Mark the differential bearings left and right before measuring them.
    Fig 35: Installing Special Tool
    G03190497Courtesy of FORD MOTOR CO.
  12. Install the special tool.
    1. Place the special tool base in a soft-jawed vise with the bearing mounting surface above the vise jaws.
    2. Position the differential bearing on the special tool base.
    3. Attach the bolt, spring, washers and spacer.
    4. Tighten the bolt.
  13. Measure the differential bearing stand height.
    1. Invert the special tool and clamp the bolt head in a vise.
    2. Position a depth micrometer flat on the differential bearing.
    Fig 36: Measuring Differential Bearing Stand Height
    G03190498Courtesy of FORD MOTOR CO.
  14. Measure both differential bearings' stand height. Record the measurement on the differential bearing shim selection procedure line D.
  15. Press the left and right differential bearing on the differential case.
    1. Position the appropriate differential bearing (LH or RH).
    2. Repeat the procedure for the opposing side.
    Fig 37: Pressing Left And Right Differential Bearing On The Differential Case
    G03190499Courtesy of FORD MOTOR CO.
  16. Install the special tools.
    Fig 38: Installing Special Tools
    G03190500Courtesy of FORD MOTOR CO.
    17. CAUTION: Overspreading may damage the differential housing.
    NOTE: Tighten and loosen the Differential Carrier Spreader screw to normalize the Housing Spreader Adapters prior to taking the final Dial Indicator reading.
    Fig 39: Spreading Differential Housing To The Specification
    G03190501Courtesy of FORD MOTOR CO.
  17. Spread the differential housing to the specification.
    1. Adjust the special tool to zero.
    2. Tighten the screw until spreading the differential housing to the specification.
    3. Remove the special tools.
    18. CAUTION: To avoid galling the case, insert shims with a light coating of grease before installing the differential case. If not carried out in this order, aluminum housing can be damaged.
    NOTE: Select the correct size differential bearing shims by completing the differential bearing shim selection chart.
    Fig 40: Placing Differential Bearing Shims In Differential Housing
    G03190502Courtesy of FORD MOTOR CO.
  18. Place the differential bearing shims in the differential housing.
  19. Install the differential case.
    1. Position the differential bearing cups on the differential bearings.
    2. Lower the differential case in place between the differential bearing shims.
    Fig 41: Installing Differential Case
    G03190503Courtesy of FORD MOTOR CO.
    20. NOTE: Hand tighten the bearing cap bolts prior to releasing the differential carrier spreader.
    Fig 42: Removing Special Tool
    G03190504Courtesy of FORD MOTOR CO.
  20. Remove the special tool.
  21. Tighten the bearing cap bolts.
    Fig 43: Tightening Bearing Cap Bolts
    G03190505Courtesy of FORD MOTOR CO.
  22. Install the special tool at the 12 o'clock position.
    Fig 44: Installing Special Tool At 12 O'Clock Position
    G03190506Courtesy of FORD MOTOR CO.
  23. Using the special tools, measure the differential ring gear backlash at four equally spaced points.
    1. Attach the special tool.
    2. Position the special tool tip centrally on a drive tooth.
    3. Zero the indicator.
    4. Turn the differential ring gear without turning the drive pinion gear. Record the indicator reading. The allowable backlash is 0.254 mm (0.010 in) to 0.305 mm (0.012 in) and must not vary more than 0.101 mm (0.004 in) between points measured. A backlash variation of more than 0.101 mm (0.004 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 45: Measuring Differential Ring Gear Backlash Using Special Tools
    G03190507Courtesy of FORD MOTOR CO.
  24. To correct for high or low backlash, increase the thickness of one differential bearing shim and decrease the thickness of the other differential bearing shim by the same amount. Refer to the following tables when adjusting the backlash. When the backlash is within specifications, install the differential assembly.
    BACKLASH SPECIFICATIONS

    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 Shim Size Chart - 4067 - 

    COLOR CODE

    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
    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 16: Differential Bearing Shim Assembly Note 

  1. Establish differential bearing preload.
    • To establish bearing preload, use the special tool to increase both the left and right shim sizes by the specification shown.
    • Use the special tool to make sure the differential bearing shims are fully seated.
    Fig 46: Using Special Tool To Make Sure The Differential Bearing Shims Are Fully Seated
    G03190508Courtesy of FORD MOTOR CO.

Item 7: 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 47: Installing Differential Drive Pinion Collapsible Spacer
    G03190509Courtesy 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.
    Fig 48: Installing Drive Pinion Gear
    G03190510Courtesy of FORD MOTOR CO.

Item 4: 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 49: Installing Rear Axle Drive Pinion Seal With Special Tool
    G03190511Courtesy of FORD MOTOR CO.
  1. Using the special tool, install the new rear axle drive pinion seal.

Item 2: Rear Axle Pinion Flange Assembly Note 

    NOTE: Disregard the index marks if installing a new rear axle pinion flange.
    Fig 50: Positioning Rear Axle Pinion Flange
    G03190512Courtesy of FORD MOTOR CO.
  1. Position the rear axle pinion flange.
    1. Lubricate the rear axle pinion flange splines.
    2. Position the rear axle pinion flange.
  2. Using the special tool, install the rear axle pinion flange.
    Fig 51: Installing Rear Axle Pinion Flange Using Special Tool
    G03190513Courtesy of FORD MOTOR CO.

Item 1: 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 Nm (inch-pound) torque wrench.
    Fig 52: Holding Pinion Flange With Special Tool
    G03190514Courtesy of FORD MOTOR CO.
  1. Use the special tool to hold the pinion flange while tightening the nut.
    • Rotate the pinion by hand, for 10 full revolutions, to make sure the differential pinion bearings seat correctly. Take frequent differential pinion bearing preload readings by rotating the pinion with a Nm (inch-pound) torque wrench.
  2. Tighten the nut to set the preload.
    • With new bearing, set preload to 1.8-3.3 Nm (16-29 lb-in).
    • With original bearings, coat bearings with new axle lubricant and set preload to 0.8-1.1 Nm (7-10 lb-in).
    Fig 53: Tightening Nut
    G03190515Courtesy of FORD MOTOR CO.
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