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Disassembly and Assembly

  1. Place the differential (4026) into the converter housing.
    2. Fig 1: Placing Differential Into Converter Housing
    G01744537Courtesy of FORD MOTOR CO.
  2. Place Shim Selection Set, Shim Gauge Adapter Ring, and the rear bearing cup onto the differential.
    3. Fig 2: Placing Shim Selection Set, Shim Gauge Adapter Ring & Rear Bearing Cup Onto Differential
    G01744538Courtesy of FORD MOTOR CO.
  3. Place the six Collars on the converter housing at the positions shown (A).
    4. Fig 3: Placing Collars On Converter Housing
    G01744539Courtesy of FORD MOTOR CO.
  4. Set the transmission case on the converter housing, then install the six Collar Bolts and Washers.
    5. Fig 4: Setting Transmission Case On Converter Housing
    G01744540Courtesy of FORD MOTOR CO.
  5. Turn the shim selection gauge to increase the clearance by using the rods until the shim selection gauge no longer turns. This seats the bearing race. Turn the shim selection gauge in the opposite direction until the preload is eliminated (gap is reduced).
    6. Fig 5: Turning Shim Selection Gauge Until Preload Is Eliminated
    G01744541Courtesy of FORD MOTOR CO.
    NOTE: Read the preload when the differential starts to turn.
    NOTE: Take several measurements and calculate the average value.
  6. Insert the Differential Rotator and attach a torque wrench to the Differential Rotator. Measure the drag on the differential bearing.
    • Adjust the clearance of the Shim Selection Gauge, using the Rods to obtain the specified preload.
    7. Fig 6: Measuring Drag On Differential Bearing
    G01744542Courtesy of FORD MOTOR CO.
    NOTE: Measure the clearance around the entire circumference. Select the shim(s) based on the largest clearance.
    NOTE: Use no more than three shims.
  7. Use a feeler gauge to measure the gap between the two halves of the shim selection gauge. Add 0.3 mm (0.0118 in) to the largest measurement. Select the shim(s) closest in value to the measurement from the General Specifications chart. Refer to GENERAL SPECIFICATIONS .
    8. Fig 7: Measuring Gap Between Two Halves Of Shim Selection Gauge
    G01744543Courtesy of FORD MOTOR CO.
  8. Remove Bolts, Washers, transmission case, Collars, shim selection gauge, and the bearing cup.
  9. Use (A) Driver Handle and (B) Bearing Cup Replacer to install the required selective shim(s) and tap the bearing cup into the transmission case.
    10. Fig 8: Installing Selective Shims & Tap Bearing Cup Into Transmission Case
    G01744544Courtesy of FORD MOTOR CO.
  10. Install the transmission case.
    11. Fig 9: Installing Transmission Case
    G01744545Courtesy of FORD MOTOR CO.
    NOTE: Take several measurements and calculate the average value.
  11. Install Differential Rotator and a torque wrench to the pinion shaft through the transmission case. Measure the bearing preload.
    12. Fig 10: Measuring Bearing Preload
    G01744546Courtesy of FORD MOTOR CO.
  12. Repeat the gauging process if the preload is not within specification.
  13. Remove the transmission case.
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