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Disassembly And Assembly: Axle: Assembly

WARNING: This page is about a different car, the 2006 Lincoln Navigator and 2006 Ford Expedition. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION: Do not omit the pinion bearing oil baffle; bearing failure can result.
    Fig 1: Positioning Drive Pinion Bearing Oil Baffle On Special Tool (205-D044)
    G04626402Courtesy of FORD MOTOR CO.
  1. If removed, position the baffle on the special tool.
  2. Using the special tool, install the baffle.
    Fig 2: Installing Drive Pinion Bearing Oil Baffle Using Special Tool (205-D044)
    G04626403Courtesy of FORD MOTOR CO.
    3. NOTE: Always install new pinion bearings when installing new pinion bearing cups.
  3. Lightly oil the new pinion bearing cups and pinion bearings with front axle lubricant.
  4. Using the special tool, install the bearing cups.
    Fig 3: Using Special Tool (205-024) To Install Drive Pinion Bearing Cups
    G04626404Courtesy of FORD MOTOR CO.
    5. NOTE: You must use the pinion bearings assembled in this procedure step at final assembly.
  5. Assemble and position the special tools and the pinion bearings in the carrier housing.
    1. Position the screw adapter.
    2. Position the aligning adapter.
    3. Position the pinion bearing.
    4. Position the gauge disc adapter.
    5. Position the gauge block adapter.
    6. Position the pinion bearing.
    7. Thread on the handle adapter.
      Fig 4: Positioning Special Tools (205-105, 205-109, 205-110, 205-111, 205-129)
      G04626405Courtesy of FORD MOTOR CO.
    6. NOTE: This step duplicates final pinion bearing preload.
  6. Tighten the special tool to simulate bearing preload.
    • Tighten to 2.2 N.m (20 lb-in).
      Fig 5: Checking Differential Pinion Bearing Preload
      G03878601Courtesy of FORD MOTOR CO.
    7. NOTE: Offset the gauge block adapter to obtain an accurate reading.
    Fig 6: Rotating Special Tool (205-110) To 45 Degrees
    G04626407Courtesy of FORD MOTOR CO.
  7. Rotate the gauge block adapter several half-turns to make sure the pinion bearings seat correctly, and position the gauge block adapter.
  8. Install the special tool.
    1. Position the special tool.
    2. Install the differential bearing caps.
    3. Install the bolts.
      • Tighten to 105 N.m (77 lb-ft).
        Fig 7: Installing Special Tool (205-336) to Position Differential Bearing Caps
        G04626408Courtesy of FORD MOTOR CO.
    9. NOTE:
    1. Use only flat, clean drive pinion bearing adjustment shims.
    2. Do not attempt to force the shim between the gauge block adapter and the gauge tube adapter. A slight drag indicates correct shim selection.
  9. Use a drive pinion bearing adjustment shim as a gauge for shim selection.
    • Check the adjustment shim thickness between the gauge block adapter and the gauge tube adapter.
    • The drive pinion stem is paint marked with a ± number for optimal gear running position. If the marking number is plus (+), subtract the number from the selected shim thickness. If the marking number is minus (-), add the number to the selected shim thickness.
    • After determining the correct shim thickness, remove the special tools.
      Fig 8: Using Drive Pinion Bearing Adjustment Shim As Gauge For Shim Selection
      G04626409Courtesy of FORD MOTOR CO.
    10. NOTE: You must use the same pinion bearings from the previous steps.
  10. Install the pinion bearing.
    • Place the drive pinion bearing adjustment shim on the pinion gear.
    • Using a suitable press and the special tool, press the pinion bearing until it is firmly seated on the pinion gear.
      Fig 9: Installing Pinion Bearing Using Special Tool (205-005) And Press
      G04626410Courtesy of FORD MOTOR CO.
  11. Place a new drive pinion collapsible spacer on the pinion stem.
    Fig 10: Locating Drive Pinion Collapsible Spacer
    G03928265Courtesy of FORD MOTOR CO.
  12. Install the outer pinion bearing.
    Fig 11: Locating Outer Pinion Bearing
    G04626412Courtesy of FORD MOTOR CO.
  13. Install the slinger.
    Fig 12: Identifying Slinger
    G04626413Courtesy of FORD MOTOR CO.
    14. NOTE: Coat the lips of the pinion seal with front axle lubricant.
    Fig 13: Locating Pinion Seal On Special Tool (205-133)
    G04626414Courtesy of FORD MOTOR CO.
  14. Place the pinion seal on the special tool.
  15. Place the special tool and seal in the pinion seal bore and drive the seal into place.
    Fig 14: Installing Pinion Seal Using Special Tool (205-133)
    G04626415Courtesy of FORD MOTOR CO.
  16. Lightly lubricate the pinion gear splines with front axle lubricant.
  17. Position the drive pinion in the housing.
    Fig 15: Locating Drive Pinion Gear
    G04583053Courtesy of FORD MOTOR CO.
    18. CAUTION: Never install the drive pinion universal joint flange with a hammer or power tools.
    NOTE: Disregard the scribe marks if installing a new flange.
    Fig 16: Positioning Universal Joint Flange On Drive Pinion
    G04626417Courtesy of FORD MOTOR CO.
  18. Align the index marks and position the universal joint flange on the drive pinion.
  19. Using the special tool, install the drive pinion universal joint flange.
    Fig 17: Identifying Special Tool (205-002)
    G04626418Courtesy of FORD MOTOR CO.
  20. Apply a small amount of lubricant to the washer side of the new pinion nut, and install the nut.
    21. CAUTION: Do not loosen the pinion nut to reduce preload under any circumstance. If it is necessary to reduce preload, install a new drive pinion collapsible spacer and pinion nut.
  21. Install the special tool, and tighten the pinion nut. Refer to the TORQUE SPECIFICATIONS  .
    • Rotate the pinion gear occasionally to make sure the pinion bearings are seating correctly. Take frequent pinion bearing torque preload readings by rotating the pinion gear with a Nm (inch-pound) torque wrench.
      Fig 18: Holding Pinion Flange Using Special Tool (205-126)
      G03928261Courtesy of FORD MOTOR CO.
      Fig 19: Tightening Pinion Nut To Specific Torque
      G04626420Courtesy of FORD MOTOR CO.
  22. Use a fine flat file to remove any burrs or nicks from the ring gear mounting surface.
    Fig 20: Identifying Burrs Or Nicks On Ring Gear Mounting Surface
    G04626421Courtesy of FORD MOTOR CO.
  23. Install the ring gear.
    1. Position 3 bolts to align the holes in the ring gear and the differential case.
    2. Using a suitable press, install the ring gear.
      Fig 21: Installing Ring Gear
      G04626422Courtesy of FORD MOTOR CO.
  24. Install the remaining bolts.
    • Tighten to 105 N.m (77 lb-ft).
      Fig 22: Identifying Differential Ring Gear Bolts
      G03878612Courtesy of FORD MOTOR CO.
    25. CAUTION: Press against the bearing inner core only.
  25. Using a suitable press and the special tool, install the differential bearings.
    1. Position the appropriate differential bearing (RH or LH).
    2. Using a suitable press and the special tool, install the differential bearing.
      • Repeat the procedure for the other differential bearing.
        Fig 23: Installing Differential Bearings
        G03878661Courtesy of FORD MOTOR CO.
  26. Install the differential carrier.
    1. Position the differential bearing cups on the differential bearings.
    2. Lower the differential carrier in place.
      Fig 24: View Of Differential Bearing Cups On Differential Bearings
      G03928292Courtesy of FORD MOTOR CO.
  27. Install a differential bearing shim of the thickness shown on the LH side of the differential bearing.
    Fig 25: Identifying Differential Bearing Shim Of Specific Thickness
    G04626426Courtesy of FORD MOTOR CO.
    28. NOTE: Apply pressure to the left side to make sure the left bearing cup is seated.
    Fig 26: Locating Left Bearing Cap
    G04626427Courtesy of FORD MOTOR CO.
  28. Install the left bearing cap and loosely install the bearing cap bolts.
  29. Install progressively thicker differential bearing shims on the right side until the thickest differential bearing shim can be inserted by hand.
    Fig 27: Installing Progressively Thicker Differential Bearing Shims
    G04626428Courtesy of FORD MOTOR CO.
  30. Install the right bearing cap and bolts.
  31. Tighten the 4 differential bearing cap bolts.
    • Tighten to 105 N.m (77 lb-ft).
      Fig 28: Identifying Differential Bearing Cap Bolts And Special Holding Fixture
      G04637391Courtesy of FORD MOTOR CO.
  32. Rotate the differential carrier to make sure it turns freely.
    Fig 29: Rotating Differential Assembly
    G03928297Courtesy of FORD MOTOR CO.
  33. Install the special tool.
    Fig 30: Installing Special Tool
    G03928309Courtesy of FORD MOTOR CO.
  34. Measure the ring gear backlash at 4 places to obtain a consistent reading.
    Fig 31: Measuring Differential Ring Gear Backlash Using Special Tools
    G03912927Courtesy of FORD MOTOR CO.
    35. NOTE: If the backlash is not within the specifications, correct it by increasing the thickness of one differential bearing shim and decreasing the thickness on the other differential bearing shim by the same amount.
    Fig 32: Locating Differential Bearing Shim
    G04626433Courtesy of FORD MOTOR CO.
  35. To increase the backlash, install a thicker differential bearing shim and a thinner differential bearing shim as shown in Fig 32.
  36. To decrease the backlash, install a thicker differential bearing shim and a thinner differential bearing shim as shown in Fig 33.
    Fig 33: Locating Differential Bearing Shim
    G04626434Courtesy of FORD MOTOR CO.
  37. Select the appropriate shim by the thickness or the stripe color.
    BACKLASH SPECIFICATIONS

    Backlash Change Required Thickness Change Required
    mm Inch mm Inch
    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 0.014 0.457 0.018
    0.381 0.015 0.508 0.020
    DIFFERENTIAL SHIM SIZE TABLE

    Stripes/Color mm Inch
    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
    1 - BLU 7.4930-7.5050 0.2950-0.2955
    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 6.9850-6.9977 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 6.1722-6.1849 0.2430-0.2335
    1 - RED 6.1214-6.1341 0.2410-0.2415
  38. Remove the 4 differential bearing cap bolts.
    • Remove the differential carrier.
      Fig 34: Identifying Differential Bearing Cap Bolts And Special Holding Fixture
      G04637391Courtesy of FORD MOTOR CO.
  39. Measure the thickness of the selected right and left bearing shims.
  40. To establish differential bearing preload, increase both the left and right differential bearing shim thickness by 0.203 mm (0.008 in).
  41. Install the special tools.
    Fig 35: Identifying Special Tools (100-002, 308-021, 205-001)
    G04626436Courtesy of FORD MOTOR CO.
    42. CAUTION: Overspreading may damage the differential housing.
    NOTE: Tighten and loosen the differential carrier spreader adapters to normalize the housing adapters prior to taking the final dial indicator reading.
  42. 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 specifications.
    3. Remove the special tools.
      Fig 36: Spreading Differential Housing Using Special Tools (100-002, 308-021)
      G04626437Courtesy of FORD MOTOR CO.
    43. CAUTION: To avoid galling the case, insert the shims with a light coating of grease before installing the differential carrier.
    Fig 37: Locating Differential Bearing Shims In Differential Housing
    G04626438Courtesy of FORD MOTOR CO.
  43. Place the differential bearing shims in the differential housing.
  44. Install the differential carrier.
    1. Position the differential bearing cups on the differential bearings.
    2. Lower the differential carrier in place between the differential bearing shims.
      Fig 38: View Of Differential Bearing Cups On Differential Bearings
      G03928292Courtesy of FORD MOTOR CO.
    45. NOTE: Hand-tighten the differential bearing cap bolts prior to releasing the special tool.
    Fig 39: Locating Differential Bearing Caps & Bolts
    G04626440Courtesy of FORD MOTOR CO.
  45. Install the differential bearing caps and bolts in their original location.
  46. Loosen and remove the special tool.
    Fig 40: Identifying Special Tool (205-001)
    G04626441Courtesy of FORD MOTOR CO.
  47. Install the special tool at the 12 o'clock position.
    Fig 41: Installing Special Tool
    G03928309Courtesy of FORD MOTOR CO.
  48. Using the special tools, recheck the ring gear backlash.
    Fig 42: Measuring Differential Ring Gear Backlash Using Special Tools
    G03912927Courtesy of FORD MOTOR CO.
  49. Apply marking compound and rotate the differential assembly 5 complete revolutions.
    Fig 43: Rotating Differential Assembly
    G03928297Courtesy of FORD MOTOR CO.
  50. Verify an acceptable pattern check. For additional information, refer to DIAGNOSIS AND TESTING .
    51. CAUTION:
    1. Remove all of the old liquid gasket, and make sure the machined surfaces are free of oil before applying the new silicone rubber.
    2. Install the axle housing tube within 15 minutes of applying the silicone or it will be necessary to remove and reapply new sealant. If possible, allow one hour before filling with lubricant to make sure the silicone sealant has cured.
    3. Do not allow any silicone rubber to squeeze inside during assembly.
  51. Assemble the axle housing tube.
    • Align the bolt holes and position the axle tube.
    • Position the axle identification tag.
    • Install the bolts.
      • Tighten to 73 N.m (54 lb-ft).
        Fig 44: Assembling Axle Housing Tube
        G04626445Courtesy of FORD MOTOR CO.
  52. Examine the axle shaft seal and bearing surface for damage. If necessary, polish the bearing surface with fine crocus cloth.
    Fig 45: Inspecting Axle Shaft Seal & Bearing Surface For Damage
    G04626446Courtesy of FORD MOTOR CO.
  53. Install a new retainer circlip on each axle shaft.
    Fig 46: Identifying Retainer Circlip Area On Axle Shaft
    G04626447Courtesy of FORD MOTOR CO.
  54. Insert the axle shafts and engage them with the side gears.
    Fig 47: Inserting Axle Shafts
    G04626448Courtesy of FORD MOTOR CO.
  55. Push in on the axle shafts until the retaining circlips expand in the side gears.
    Fig 48: Pushing In On Axle Shafts
    G04626449Courtesy of FORD MOTOR CO.
  56. Remove the axle assembly from the Holding Fixture and place it on the bench.
    57. CAUTION:
    1. Remove all of the old liquid gasket, and make sure the machined surfaces are free of oil before applying the new silicone rubber.
    2. Install the differential housing cover within 15 minutes of applying the silicone, or it will be necessary to remove and reapply new sealant. If possible, allow one hour before filling with lubricant to make sure the silicone sealant has cured.
    Fig 49: Filling Sealing Groove On Differential Housing Cover With Silicone Gasket & Sealant
    G04626450Courtesy of FORD MOTOR CO.
  57. Fill the sealing groove on the differential housing cover with silicone gasket and sealant.
  58. Install the differential housing cover.
    Fig 50: Identifying Differential Housing Cover & Bolts
    G04626451Courtesy of FORD MOTOR CO.
  59. Fill the differential carrier housing, and install the fill plug.
    • Use rear axle lubricant.
      Fig 51: Identifying Filling Specification Of Differential Carrier Housing Lubricant
      G04626452Courtesy of FORD MOTOR CO.
  60. Install the front drive axle assembly. For additional information, refer to AXLE ASSEMBLY .
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