Disassembly and Assembly
Axle-Nodular Iron
Special Tool(s)
DISASSEMBLY
1. Remove the differential housing cover.
2. NOTE: The Differential Housing (Plate) Spreader is used here to give the rear axle housing stability. Do not spread the rear axle housing.
Mount the rear axle housing on the Transmission Holding Fixture.
1 Attach the Differential Housing (Plate) Spreader to the rear axle housing with four cover bolts.
2 Attach the Differential Housing (Plate) Spreader to the Transmission Holding Fixture with two 3/8 inch x 1-1/2 inch bolts.
3. NOTE: Mark the position of the bearing caps as arrows may not be visible. The bearing caps must be installed in their identical locations and positions.
Remove the differential bearing caps.
4. Remove the differential case.
5. Remove the 10 ring gear bolts.
6. CAUTION: Care should be taken not to damage the bolt hole threads.
Insert a punch in opposing bolt holes and drive the ring gear off.
7. Using the special tools, remove the differential bearing.
^ Repeat for the other side.
8. Remove the differential pinion shaft lock bolt.
9. Remove the differential pinion shaft.
10. Rotate and remove the differential gears and thrust washers.
11. Remove the differential side gears and thrust washers.
12. Mark the pinion flange in relation to the drive pinion stem to make sure of correct alignment during installation.
13. CAUTION: After removing the pinion nut, discard it. Use a new nut for installation.
Remove the pinion nut.
^ Install the special tool.
^ Install a suitable breaker bar and remove the nut.
14. Using the special tool, remove the pinion flange.
15. Install the special tool and, with a soft-faced hammer, drive the pinion out of the front bearing cone and remove it through the rear of the housing.
^ Remove the rear axle drive pinion shaft oil slinger, the rear axle drive pinion seal, the outer pinion bearing and the collapsible spacer.
16. Remove the inner pinion bearing.
1 Position the special tool under the pinion bearing.
2 Using a press, remove the pinion bearing.
17. NOTE: Measure the drive pinion bearing adjustment shim, which is found under the inner differential pinion bearing, with a micrometer and record the thickness (use this as a reference to compare the shim gauge reading prior to installing the inner differential pinion bearing).
Remove the drive pinion bearing adjustment shim.
18. If required, remove the rear axle outer pinion bearing cup from the rear differential housing using the special tools.
19. If required, remove the rear axle inner pinion bearing cup from the rear differential housing using the special tools.
ASSEMBLY
Differential Carrier
1. CAUTION: Lubricate the differential side gear thrust washers with Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B prior to installation.
Install the differential side gears and the differential pinion thrust washers in the differential case.
2. CAUTION: Lubricate the differential pinion thrust washers with Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B prior to installation.
Install the differential pinion gears and the differential pinion thrust washers in the differential case.
^ Rotate the pinion gears to align with the pinion shaft holes.
3. NOTE: If a new pinion shaft lock bolt is unavailable, coat the threads with Threadlock and Sealer E0AZ-19554-AA or equivalent meeting Ford specifications WSK-M2G351-A5 prior to installation.
Install the differential pinion shaft and install a new differential pinion shaft lock bolt.
4. Use the special tool to install the differential bearing on the differential case. Repeat for the other side.
5. Draw-file the differential ring gear mounting surface to remove any nicks or burrs.
6. Press the ring gear on the differential case.
^ Start three of the ring gear bolts through the differential case and into the ring gear to make sure the ring gear bolt holes align with the differential case bolt holes correctly.
7. Install the ring gear bolts.
^ Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to the ring gear bolts.
^ Set carrier assembly aside.
Drive Pinion
8. If required, install a new rear axle inner pinion bearing cup in the rear differential housing.
9. If required, install a new rear axle outer pinion bearing cup in the rear differential housing.
10. NOTE: Using the threaded drawbar included in 205-054 is an optional method of installing new inner and the outer pinion bearing cups.
NOTE: Coat the new rear axle pinion bearing cup with SAE 5W-30 Super Premium Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.
Install the pinion bearing cups.
1 Position the new rear axle pinion bearing cups on the special tool.
2 Position the bearing cup replacer in the rear axle differential housing.
3 Tighten the special tool to fully seat the rear axle pinion bearing cups in the bore.
11. NOTE: A drive pinion bearing adjustment shim is used between the pinion bearing and the pinion head. The drive pinion bearing adjustment shim compensates for machining variations in the differential pinion and the pinion bearings. The correct drive pinion bearing adjustment shim size will locate the pinion for correct tooth contact with the ring gear. Selecting the correct drive pinion bearing adjustment shim can be done using a pinion depth gauge set.
NOTE: Apply a light film of SAE 75W-140 Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A on the outer differential pinion bearing and the inner differential pinion bearing assemblies.
Install the special tools.
12. NOTE: This step duplicates pinion bearing preload.
Thread the handle onto the screw and tighten to the specification shown.
13. NOTE: The special tool must be offset to obtain an accurate reading.
NOTE: Rotate the special tool several half turns to correctly seat the pinion bearings.
Position the special tool 45 degrees as shown.
14. Install the special tool.
1 Position the special tool on the differential bearing seat of the rear axle housing.
2 Install the differential bearing caps.
3 Install the differential bearing cap bolts and tighten to specification.
15. NOTE: A slight drag should be felt for the correct shim selection.
NOTE: Use the original recorded shim thickness as a starting point.
Select and check the correct shim size.
16. Remove the special tool.
17. NOTE: The same pinion bearings and drive pinion bearing adjustment shim used in the drive pinion shim selection procedure must be used in the final axle assembly.
Install the inner pinion bearing.
1 Position the drive pinion bearing adjustment shim on the pinion stem.
2 Position the pinion bearing on the pinion stem.
3 Position the special tool on the pinion stem.
4 Using a press, firmly seat the drive pinion bearing adjustment shim and pinion bearing on the pinion stem.
18. NOTE: Make sure the splices on the pinion stem are free of burrs. If burrs are evident, remove using a fine crocus cloth.
Place a new drive pinion collapsible spacer on the pinion stem against the pinion stem shoulder.
19. Install the outer pinion bearing, the rear axle drive pinion shaft oil slinger and the rear axle drive pinion seal, using the special tool.
20. Install the drive pinion and drive pinion collapsible spacer into the rear axle housing.
21. NOTE: Lubricate the rear axle pinion flange splices. Use SAE 75W-140 Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.
NOTE: Disregard the scribe marks if a new rear axle pinion flange or gearset is being installed.
Align the rear axle pinion flange with the drive pinion shaft.
22. NOTE: Always use a new pinion nut.
With the drive pinion in place in the rear axle housing, install the rear axle pinion flange using the special tools.
23. CAUTION: Do not under any circumstance loosen the pinion nut to reduce preload. If it is necessary to reduce preload, install a new collapsible spacer and pinion nut.
Use the special tool to hold the pinion flange while tightening the new pinion nut.
^ Rotate the pinion occasionally to make sure the differential pinion bearings seat correctly. Take frequent differential pinion bearing torque preload readings by rotating the pinion with a Nm (inch-pound) torque wrench.
Carrier Shim Selection
24. Place the differential case/gear subassembly with the differential bearings and cups in the rear axle housing.
25. Install a differential bearing shim with the thickness of 6.73 mm (0.265 inch) on the LH side of the differential case.
26. Install the LH bearing cap finger-tight.
27. NOTE: Apply pressure toward the left side to fully seat the differential bearing cup.
Install progressively larger differential bearing shims on the RH side until the largest differential bearing shim selected can be assembled with a slight drag feel.
28. Install the RH bearing cap.
^ Tighten both bearing caps to specification.
Measuring For Backlash
29. NOTE: Measure the ring gear backlash at four places to obtain a consistent reading.
NOTE: Rotate the differential by turning the ring gear.
Measure the backlash.
^ If the backlash is within specification, refer to "Backlash within specification".
^ If a zero backlash condition occurs, refer to "Zero backlash".
^ If backlash readings vary by more than 0.076 mm (0.003 inch) in any of the four recorded readings, refer to "Ring gear runout".
^ If the backlash is not within specification, refer to "Backlash not within specification".
Zero Backlash
30. If a zero backlash condition occurs, add 0.5 mm (0.020 inch) to the RH side and subtract 0.5 mm (0.020 inch) from the LH side to allow backlash indication.
^ Check the backlash. Repeat "Measuring ring gear backlash".
Ring Gear Runout
31. NOTE: Identify the right and left side bearing cups and shims for installation location.
Remove the differential case.
32. Remove the ring gear.
33. Install the differential case and carrier bearing shims without the ring gear.
^ Rotate the differential case to correctly seat the differential bearings.
34. Check the differential case flange runout using the special tool.
^ If the runout is within specifications, install a new ring and pinion gearset.
^ If the runout exceeds specifications, install a new differential case.
^ Recheck the runout with the new differential case and bearings.
Backlash Not Within Specification
35. To increase or decrease the backlash, remove the bearing caps and install a thicker shim or a thinner shim as shown.
^ 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.
36. Rotate the differential several times to make sure the differential bearings are correctly seated.
^ Rotate the differential by turning the ring gear.
37. Use the special tool to make sure the backlash is adjusted to specifications.
^ If the backlash is not within specification, repeat Step 34.
Backlash Within Specification
38. Remove the bearing caps and bolts.
^ To establish differential bearing preload, use the special tool to increase both left and right shim sizes by 0.152 mm (0.006 inch).
^ Use the special tool to make sure that the differential bearing shims are fully seated and the assembly turns freely.
39. Install the bearing caps and bolts and tighten them to specification.
40. Use the special tool to recheck the backlash.
41. CAUTION: Make sure the machined surfaces on both the rear axle housing and the differential housing cover are clean and free of oil before installing the new silicone sealant. The inside of the rear axle must be covered when cleaning the machined surface to prevent contamination.
Install the differential housing cover.
^ Apply a new continuous bead of sealant to the differential housing cover. Use Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specifications ESB-M4G92-A.
42. Install the rear axle.
43. Refill the rear axle.
^ Fill the rear axle 3 - 5 mm (1/8 - 3/16 inch) from the bottom of the filler hole with SAE 75W-140 Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.