Axle-Nodular Iron

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 the 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. Remove the differential gears.





11. Remove the differential side gears.





12. Install a Nm (inch/pound) torque wrench on the pinion nut and record the torque necessary to maintain rotation of the drive pinion gear through several revolutions.





13. Mark the pinion flange in relation to the drive pinion stem to ensure correct alignment during installation.





14. CAUTION: After removing the pinion nut, discard it. Use a new nut for installation.

NOTE: Make sure to insert the cotter key into the special tool as shown.

Remove the pinion nut.
^ Install the special tool.
^ Install a suitable breaker bar and remove the nut.





15. Using the special tool, remove the pinion flange.





16. 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 and the collapsible spacer.





17. Remove the front pinion bearing.
1 Position the special tool under the pinion bearing.
2 Using a press, remove the pinion bearing.





18. NOTE: Measure the drive pinion bearing adjustment shim, which is found under the 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 differential pinion bearing).

Remove the drive pinion bearing adjustment shim.





19. Remove damaged rear axle pinion bearing cup from the rear axle housing using the special tools.





20. Remove damaged rear axle pinion bearing cup from the rear axle housing using the special tools.

ASSEMBLY

All vehicles





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 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 with the differential pinion thrust washers in the differential case.





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. Install the differential case without the ring gear.
^ Rotate the differential case to correctly seat the differential bearings.





6. Check the differential case flange runout using the special tool.
^ If the runout is within specification, install a new ring gear and pinion. If the runout exceeds specification, the ring gear is true and the concern is due to either a damaged differential case or differential bearings.
^ Inspect the differential bearings. If the differential bearings are not damaged, install a new differential case and the differential bearings.
^ Recheck the runout with the new differential case and differential bearings.
7. Remove the differential case.





8. Press the ring gear on the differential case.
^ Start two 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.





9. Install the ring gear bolts.
^ Apply Stud and Bearing Mount E0AZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to the ring gear bolts.





10. NOTE: If the ring gear runout check (carried out before disassembly) exceeds specification, the cause may be a warped ring gear, a damaged differential case or loss of differential bearing preload.

With the pinion removed, place the differential case/gear subassembly with the differential bearing and the rear axle pinion bearing cups in the rear axle housing.





11. Install a differential bearing shim of the thickness shown on the LH side of the differential case.





12. Install the LH bearing cap finger-tight.





13. 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.





14. Install the RH bearing cap.
^ Tighten both bearing caps to specification.





15. Rotate the differential assembly to make sure it rotates freely.
16. Remove the differential case. Pinion bearing cup installation with special tool 205-153,205-480, and 205-054.





17. Install a new inner rear axle pinion bearing cup in the rear axle housing.





18. Install a new outer rear axle pinion bearing cup in the rear axle housing.





Pinion bearing cup installation with special tool 205-054

19. 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 cup.
1 Position the rear axle pinion bearing cup on the special tool.
2 Position the bearing cup replacer in the rear axle housing.
3 Tighten the special tool to fully seat the rear axle pinion bearing cup in the bore.








All vehicles

20. 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 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A on the front differential pinion bearing and the rear differential pinion bearing assemblies.

Install the special tools.





21. NOTE: This step duplicates pinion bearing preload.

Thread the Handle onto the Screw and tighten to the specification shown.





22. 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.





23. 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.





24. NOTE: A slight drag should be felt for the correct shim selection.

NOTE: Use a shim to determine shim thickness. Select and check the correct shim size.
25. Remove the special tool.





26. 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.





27. NOTE: Make sure the splines on the pinion stem are free of burrs. If burrs are evident, remove using a fine crocus cloth, working a rotational motion.

Place a new drive pinion collapsible spacer on the pinion stem against the pinion stem shoulder.





28. Install the drive pinion and drive pinion collapsible spacer into the rear axle housing.
29. Install the outer pinion bearing, the rear axle drive pinion shaft oil slinger and the rear axle drive pinion seal.





30. NOTE: Lubricate the rear axle pinion flange splines. Use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2CI92-A.

Install the rear axle pinion flange.

NOTE: Disregard the scribe marks if a new rear axle pinion flange is being installed.

Align the rear axle pinion flange with the drive pinion shaft.





31. With the drive pinion in place in the rear axle housing, install the rear axle pinion flange using the special tools.








32. 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 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.





33. NOTE: Apply a light coating of Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B to the differential bearing shim to help hold in place.

NOTE: Select the correct size differential bearing shims by using the differential bearing shim selection chart.

Install the differential bearing shims.
^ Place the differential bearing shims in the rear axle housing.





34. 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.





35. Install the bearing caps in their original positions and tighten the bolts to specification.





36. Move the Dial Indicator Gauge to the 12 o'clock position.








Measuring for backlash

37. NOTE: Measure the ring gear backlash at four places to obtain a consistent reading.

NOTE: Turn the ring gear without turning the pinion 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 the backlash is not within specification, refer to Backlash not within specification.

Zero backlash
38. If a zero backlash condition occurs, add 0.51 mm (0.02 inch) to the RH side and subtract 0.51 mm (0.02 inch) from the LH side to allow backlash indication.
^ Check the backlash. Repeat Measuring ring gear backlash.





Backlash not within specification
39. 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.





40. Rotate the differential several times to make sure the differential bearings are correctly seated.
^ Do not turn the pinion flange in order to rotate the differential.
41. Use the special tool to recheck the backlash.
^ If the backlash is within specification, refer to Backlash within specification. If the backlash is not within specification, repeat Measuring ring gear backlash.





Backlash within specification
42. Remove the bearing caps and bolts.
^ To establish differential bearing preload, use the special tool to increase both left and right shim sizes by the specification shown.
^ Use the special tool to make sure that the differential bearing shims are fully seated and the assembly turns freely.





43. Install the bearing caps and bolts and tighten them to specification.





44. Use the special tool to recheck the backlash.





45. 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.
46. Install the rear axle.
47. Refill the rear axle.
^ Fill the rear axle 3 - 5 mm (1/8 - 3/16 inch) from the bottom of the filler hole with SAL 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.