Disassembly And Assembly

1. Place the vehicle in NEUTRAL and position on a hoist. For additional information, refer to JACKING & LIFTING .
2. Remove the front axle assembly from the vehicle. For additional information, refer to FRONT AXLE ASSEMBLY .
3. Remove the parts in the order indicated in the following illustration and table.
   Fig 1: Exploded View Of Differential(1 Of 2)

   Courtesy of FORD MOTOR CO.
   Fig 2: Exploded View Of Differential(2 Of 2)

   Courtesy of FORD MOTOR CO.
4. To assemble, reverse the disassembly procedure.
5. Fill the axle to the specified fluid level with the fluid listed in Specifications.

Item 1: Pinion Nut and Washer Disassembly Note 

1. Measure and record the pinion bearing torque preload.
   • Using a Nm (inch-pound) torque wrench, rotate the pinion. Measure the torque required to maintain pinion rotation.
   Fig 3: Measuring Torque Required To Maintain Pinion Rotation

   Courtesy of FORD MOTOR CO.
2. Index-mark the pinion flange and the pinion stem.
   Fig 4: Identifying Index-Mark On Pinion Flange

   Courtesy of FORD MOTOR CO.
3. Using the special tool to hold the pinion flange, remove and discard the pinion nut and washer.
   Fig 5: Holding Pinion Flange Using Special Tool

   Courtesy of FORD MOTOR CO.

Item 2: Pinion Flange Disassembly Note 

1. Using the special tool, remove the pinion flange.
   Fig 6: Removing Pinion Flange Using Special Tool

   Courtesy of FORD MOTOR CO.
2. Inspect the pinion flange for burrs and damage. Inspect the end of the pinion flange that contacts the bearing cone, the nut counterbore, and the seal surface for nicks. Discard the pinion flange if damaged.

Item 4: Pinion Oil Seal Disassembly Note 

1. Using the special tool, remove the pinion seal.
   Fig 7: Removing Pinion Seal Using Special Tool

   Courtesy of FORD MOTOR CO.

Item 8: Axle Shaft Oil Seal Disassembly Note 

1. Using the special tool, remove the axle seal.
   Fig 8: Removing Axle Seal Using Special Tool

   Courtesy of FORD MOTOR CO.

Item 9: Axle Shaft Bearing Disassembly Note 

1. Using the special tool, remove the axle shaft bearing.
   Fig 9: Removing Axle Shaft Bearing Using Special Tool

   Courtesy of FORD MOTOR CO.

Item 14: Differential Case Disassembly Note 

1. Install the special tool.
   Fig 10: Installing Special Tool

   Courtesy of FORD MOTOR CO.
2. Install the axle assembly into the bench fixture.
   Fig 11: Installing Axle Assembly Into Bench Fixture

   Courtesy of FORD MOTOR CO.
3. Install the special tools.
   Fig 12: Installing special tools

   Courtesy of FORD MOTOR CO.
CAUTION: Overspreading can damage the differential housing.
Fig 13: Spreading Differential Housing To The Specification
Courtesy of FORD MOTOR CO.
4. Spread the differential housing to the specification.
   1. Adjust the special tool to zero.
   2. Tighten the differential carrier spreader screw.
   3. Remove the dial indicator.
CAUTION: Use wood blocks to avoid damaging the differential housing.
Fig 14: Removing Differential Assembly
Courtesy of FORD MOTOR CO.
5. Remove the differential assembly from the housing.
   1. Position the wood blocks.
   2. Push downward on the pry bars.
   3. Remove the differential assembly.
   4. Remove the special tool.

Item 16: Inner Pinion Bearing Disassembly Note 

1. Press the differential inner pinion bearing off the pinion.
   1. Install special tool under the pinion bearing.
   2. Using a shop press, remove the bearing from the pinion.
   Fig 15: Pressing Differential Inner Pinion Bearing Off The Pinion

   Courtesy of FORD MOTOR CO.

Item 17: Pinion Position Shim Disassembly Note 

1. Measure and record the thickness of the pinion position shim for reference during assembly.
   Fig 16: Identifying Pinion Positioning Shim

   Courtesy of FORD MOTOR CO.

Item 18: Inner Pinion Bearing Cup Disassembly Note 

1. To prevent it from cocking in the bore, remove the inner pinion bearing cup by tapping alternately on each side of the cup with a brass drift.
   Fig 17: Removing Inner Pinion Bearing Cup

   Courtesy of FORD MOTOR CO.

Item 20: Outer Pinion Bearing Cup Disassembly Note 

1. To prevent it from cocking in the bore, remove the outer pinion bearing cup by tapping alternately on each side of the cup with a brass drift.
   Fig 18: Removing Outer Pinion Bearing Cup

   Courtesy of FORD MOTOR CO.

Item 24: Differential Bearing Disassembly Note 

1. Assemble the special tools.
   Fig 19: Assembling Special Tools

   Courtesy of FORD MOTOR CO.
2. Position the special tool on the differential bearing.
   Fig 20: Positioning Special Tool On Differential Bearing

   Courtesy of FORD MOTOR CO.
3. Using the special tool, remove the bearing.
   Fig 21: Removing Bearing Using Special Tool

   Courtesy of FORD MOTOR CO.

Item 32 and 33: Axle Isolator Bushing Disassembly Note 

1. Place the special tool on the isolator and index-mark the housing in line with the arrow on the special tool.
   Fig 22: Indexing Housing In Line With The Arrow On The Special Tool

   Courtesy of FORD MOTOR CO.
2. Using a feeler gauge, measure the gap between the isolator flange and the axle housing.
   Fig 23: Measuring Gap Between Isolator Flange And Axle Using Feeler Gauge

   Courtesy of FORD MOTOR CO.
3. Tap the special tool on, between the axle housing and the isolator flange.
   Fig 24: Taping Special Tool Between Axle Housing And The Isolator Flange

   Courtesy of FORD MOTOR CO.
4. Assemble the remaining special tools and remove and discard the isolator.
   Fig 25: Removing Isolator Using Special Tools

   Courtesy of FORD MOTOR CO.

Item 32 and 33: Axle Isolator Bushing Assembly Note 

1. Position the new isolator in the housing bore and install the special tools. Align the arrow on the special tool with the index mark on the housing.
   Fig 26: Aligning Arrow On Special Tool With Index Mark

   Courtesy of FORD MOTOR CO.
2. Tighten the drawbolt to install the isolator.
   • Draw the isolator into the housing to the gap measured when the isolator was removed.
   Fig 27: Tightening Drawbolt To Install Isolator

   Courtesy of FORD MOTOR CO.

Item 25: Differential Bearing Shim Assembly Note 

1. Install the special tool.
   Fig 28: Installing Special Tool

   Courtesy of FORD MOTOR CO.
2. Install the differential case in the differential housing.
   Fig 29: Installing Differential Case In Differential Housing

   Courtesy of FORD MOTOR CO.
NOTE: Repeat this step until obtaining a consistent reading.
Fig 30: Measuring Total End Play
Courtesy of FORD MOTOR CO.
3. Measure the total end play.
   1. Install the special tool.
   2. Force the differential case as far as possible away from the indicator. Position the indicator tip on the machined surface and adjust it to measure full travel. With force still applied, set the indicator to zero.
   3. Force the differential case as far as possible in the opposite direction.
   4. Record the total end play reading on the Differential Bearing Shim Selection Procedure Worksheet, Line A in this procedure.
4. Remove the special tool, then remove the differential case.
   • Remove the special tool.
   • Remove the differential case.
   Fig 31: Removing Special Tool

   Courtesy of FORD MOTOR CO.
CAUTION: Do not reuse the original bolts.
Fig 32: Installing Differential Ring Gear
Courtesy of FORD MOTOR CO.
5. Using a suitable press, install the differential ring gear.
   1. Position the differential ring gear and the differential case. Start two or three new bolts to align the holes in the ring gear and the differential case.
   2. Using a suitable press, install the differential ring gear.
6. Install the remaining new bolts. Tighten all of the bolts to specification.
   Fig 33: Tightening Bolts

   Courtesy of FORD MOTOR CO.
7. Install the special tool, and position the assembly in the differential housing.
   1. Install the special tool.
   2. Position the assembly in the differential housing.
   Fig 34: Installing Special Tool

   Courtesy of FORD MOTOR CO.
8. Position the special tool.
   Fig 35: Positioning Special Tool

   Courtesy of FORD MOTOR CO.
9. Force the differential ring gear into mesh with the pinion gear (zero backlash). With force still applied, set the special tool to zero.
   Fig 36: Setting Special Tool To Zero

   Courtesy of FORD MOTOR CO.
10. Force the differential ring gear away from the pinion gear as far as possible. Record the reading on the Differential Bearing Shim Selection Procedure Worksheet, Line D in this procedure.
    Fig 37: Forcing Differential Ring Gear Away From Pinion Gear

    Courtesy of FORD MOTOR CO.
11. Remove the special tool.
    Fig 38: Removing Special Tool

    Courtesy of FORD MOTOR CO.
12. Remove the differential case from the differential housing. Remove the special tool from the differential case hubs.
    Fig 39: Removing Special Tool From Differential Case Hubs

    Courtesy of FORD MOTOR CO.
13. Complete the worksheet, and select the appropriate thickness differential shims. New differential shims are available in 0.0762 mm (0.003 in), 0.127 mm (0.005 in), 0.254 mm (0.010 in), and 0.762 mm (0.030 in) thickness.

    Differential Bearing Shim Selection Procedure Worksheet 

    ITEM
    
    

    Line	Item	Result (actual) mm (in)	Result (example) mm (in)
    A	Total end play reading (without gears)	2.032 (0.080)
    B	Add preload	+0.2032 (+0.008)	+0.2032 (+0.008)
    C	Total (add A and B)		2.2352 (0.088)
    D	End play measurement (with gears)		1.0414 (0.041)
    E	Subtract the shim thickness on the ring gear side	-0.0762 (-0.003)	-0.0762 (-0.003)
    F	Total (subtract E from D) (thickness of shims to place on the ring gear side)		0.9652 (0.038)
    G	Total (subtract F from C) (thickness of shims to place on the drive pinion side)		1.27 (0.050)

Item 24: Differential Bearings Assembly Note 

1. Install the differential shims and the differential bearing.
   1. Position the differential shims and the differential bearing.
   2. Using a suitable press, install the differential bearing.
      • Repeat this step for opposite side of the differential case.
      • Most axles will have the larger amount of shims on the ring gear side and the smaller amount on the case side.
   Fig 40: Installing Differential Shims And Differential Bearing

   Courtesy of FORD MOTOR CO.

Item 18 and 20: Inner and Outer Pinion Bearing Cup Assembly Note 

CAUTION: Always install new differential pinion bearings when installing new differential drive pinion bearing cups.
1. Lubricate the new differential drive pinion bearing cups.
2. Using the special tools, install the differential drive pinion bearing cups.
   Fig 41: Installing Differential Drive Pinion Bearing Cups Using Special Tools

   Courtesy of FORD MOTOR CO.

Item 17: Pinion Position Shim and Item 16: Inner Pinion Bearing Assembly Note 

NOTE: Apply a light film of oil to the differential pinion bearings before installing them.
Fig 42: Assembling Special Tool And Installing In Differential Housing
Courtesy of FORD MOTOR CO.
1. Assemble and position the following in the differential housing.
   1. Position the Screw.
   2. Position the Aligning Adapter.
   3. Position the inner differential pinion bearing.
   4. Position the Gauge Disc.
   5. Position the Gauge Block.
   6. Position the outer differential pinion bearing.
   7. Thread on the Handle.
2. Using a Nm (inch-pound) torque wrench, tighten the Handle.
   Fig 43: Tightening Handle

   Courtesy of FORD MOTOR CO.
NOTE: Offset the Gauge Block to obtain an accurate reading.
Fig 44: Positioning Special Tool
Courtesy of FORD MOTOR CO.
3. Rotate the Gauge Block several half turns to make sure the differential pinion bearings seat correctly. Position the special tool as shown.
4. Install the special tool and the paper shipping tags.
   1. Position the special tool and the paper shipping tags.
   2. Install the differential bearing caps.
   3. Install the bolts.
   Fig 45: Installing Special Tool And Paper Shipping Tags

   Courtesy of FORD MOTOR CO.
NOTE: Use a feeler gauge, or flat, clean drive pinion position shims as a measuring device.
NOTE: Selection of a shim that is too thick results in deep tooth contact at final assembly. Do not attempt to force the gauge or shim between the Gauge Block and the Gauge Tube. A slight drag indicates a correct selection.
Fig 46: Checking Shim Selection
Courtesy of FORD MOTOR CO.
5. Using a feeler gauge, or a flat, clean drive pinion position shim, measure between the Gauge Block and the Gauge Tube. Record the measurement.
   • Remove the special tools after determining the correct shim thickness.
6. Select the correct thickness drive pinion position shim.
   • New drive pinion position shims are available in the following sizes:
   SPECIFICATION
   
   

   mm	Inch
   1.35	0.053
   1.40	0.055
   1.45	0.057
   1.50	0.059
   1.55	0.061
   1.60	0.063
   1.65	0.065
   1.70	0.067
   1.75	0.069
   1.80	0.071
   1.85	0.073

   • If installing a new gearset, notice the plus (+), minus (-), or zero (0) etching on the new drive pinion, and adjust the thickness of the new shim. If etching is plus (+), subtract the number from the gauged shim thickness. If etching is minus (-), add the number to the gauged shim thickness.
   Fig 47: Identifying Plus (+), Minus (-), Or Zero (0) Etching On The New Drive Pinion

   Courtesy of FORD MOTOR CO.
7. Install the pinion position shim and the differential pinion bearing.
   • Using the special tool and a suitable press, seat the differential pinion bearing firmly against the pinion position shim.
   Fig 48: Installing Pinion Position Shim

   Courtesy of FORD MOTOR CO.

Item 14: Differential Case Assembly Note 

1. Install the special tools.
   • Position the clutch housing gauge needle in the differential carrier spreader adapter hole.
   Fig 49: Installing Special Tools

   Courtesy of FORD MOTOR CO.
CAUTION: Overspreading can damage the differential housing.
Fig 50: Spreading Differential Housing To Specification
Courtesy of FORD MOTOR CO.
2. Spread the differential housing to the specification.
3. Remove the special tools.
   Fig 51: Removing Special Tools

   Courtesy of FORD MOTOR CO.
NOTE: Push the differential case downward to fully seat the differential bearing cups in the differential housing.
Fig 52: Installing Differential Bearing Cups
Courtesy of FORD MOTOR CO.
4. Install the differential bearing cups and the differential case in the differential housing.
   1. Position the differential bearing cups on the differential bearings.
   2. Lower the differential case in place.
CAUTION: Do not tighten the bolts to specification at this time.
Fig 53: Installing Differential Bearing Caps
Courtesy of FORD MOTOR CO.
5. Install the differential bearing caps in their original positions.
   1. Position the differential bearing caps.
   2. Install the bolts hand-tight.
6. Remove the special tools.
   Fig 54: Removing Special Tools

   Courtesy of FORD MOTOR CO.
7. Tighten the bolts.
   Fig 55: Tightening Bolts

   Courtesy of FORD MOTOR CO.
8. Verify that the differential case rotates freely.
9. Using the special tools, measure the backlash at three equally spaced points on the differential ring gear.
   1. Mount the special tool.
   2. Position the special tool.
   3. Zero the indicator.
   4. Turn the differential ring gear without turning the pinion gear. Record the measurement.
      • The backlash tolerance is 0.13 mm (0.005 in) to 0.20 mm (0.008 in) and cannot vary more than 0.05 mm (0.002 in) between points checked. A backlash variation of more than 0.005 mm (0.002 in) indicates gear/case runout.
      • If the backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness of the other differential bearing shim by the same amount.
   Fig 56: Measuring Backlash Using Special Tools

   Courtesy of FORD MOTOR CO.

Item 9: Axle Shaft Bearing Assembly Note 

1. Using the special tools, install the axle tube bearing.
   Fig 57: Installing Axle Tube Bearing Using Special Tools

   Courtesy of FORD MOTOR CO.

Item 8: Axle Shaft Oil Seal Assembly Note 

1. Using the special tools, install the axle shaft oil seal.
   Fig 58: Installing Axle Shaft Oil Seal Using Special Tools

   Courtesy of FORD MOTOR CO.

Item 4: Pinion Oil Seal Assembly Note 

NOTE: Lubricate the pinion seal.
NOTE: Pinion seal must be fully seated all the way around or pinion seal damage will occur.
Fig 59: Installing Pinion Seal Using Special Tool
Courtesy of FORD MOTOR CO.
1. Using the special tool, install the pinion seal.

Item 2: Pinion Flange Assembly Note 

CAUTION: Never use a metal hammer on the pinion flange or install the flange with power tools.
NOTE: Lubricate the pinion flange splines.
Fig 60: Installing Pinion Flange Using Special Tool
Courtesy of FORD MOTOR CO.
1. Align the index marks. Using the special tool, install the pinion flange.

Item 1: Pinion Nut and Washer Assembly Note 

CAUTION: Do not loosen the nut to reduce preload. Install a new collapsible spacer and nut if preload reduction is necessary.
Fig 61: Holding Pinion Flange And Tightening Nut Using Special Tool
Courtesy of FORD MOTOR CO.
1. Using the special tool to hold the pinion flange, tighten the nut to set the preload.
   • Tighten the nut, rotating the pinion occasionally to make sure the differential pinion bearings are seating correctly. Take frequent differential pinion bearing preload readings by rotating the pinion with a Nm (inch-pound) torque wrench. The final reading must be 0.56 Nm (5 lb-in) more than the initial reading taken during removal.