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Balance Shaft Backlash: Check

  1. Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC  Timing Peg. The engine is now at TDC  .

    Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC  .

    G09599748
  2. Mark the balancer unit and shafts on the top for reference that the balancer unit is at TDC  .
    G09599749
  3. NOTE: Due to the precision interior construction of the balancer unit, it should not be disassembled.
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  4. Remove the adjustment shims from the seat faces of the balancer unit.
  5. NOTE: Visually inspect the balancer unit gear for damage and verify that the shaft turns smoothly. If there is any damage or malfunction, replace the balancer unit.

    Install the master adjustment shims (No. 50) on the seat faces of the balancer unit.

  6. With the balancer unit shaft marks at the TDC  position, slowly install the balancer unit to the cylinder block to avoid interference between the crankshaft drive gear and the balancer unit driven gear.
    G09599751
  7. Torque  :

    Stage 1: 18 lb.ft (25 Nm)

    Stage 2: 31 lb.ft (42 Nm)

    G09599752
  8. Rotate the crankshaft to confirm that there are no meshing problems between the balancer unit gear and the crankshaft gear.

    Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC  .

    G09599753
  9. Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC  Timing Peg. The engine is now at TDC  .

    Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC  .

    G09599754
  10. NOTE: Measure the backlash and verify that it is within specified range at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. It will be necessary to reset the measuring equipment between measurements.
    NOTE: The measurement must be taken with the Dial Indicator Gauge with Holding Fixture, a 5-mm Allen wrench and worm clamp set up as shown in illustration below. Mark the Allen wrench with a file 80 mm (3.149 in) above the driven gear shaft center. Make sure the worm clamp and Allen wrench are not touching the balance shaft housing.
    NOTE: For an accurate measurement while measuring the gear backlash, insert a screwdriver as shown in illustration below, into the crankshaft No. 1 crankweight area and set both the rotation and the thrust direction with the screwdriver, using a prying action as shown in illustration below.
    • Position as shown in illustration below. Measure the gear backlash.

      Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge  .

    • Position the Dial Indicator Gauge with Holding Fixture (1) on the Allen wrench 80 mm (3.149 in) above the driven gear shaft center (2) on the balancer unit.
    • Rotate the crankshaft clockwise and measure the backlash at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees.
      G09599755
  11. NOTE: If maximum backlash exceeds 0.120 mm (0.0047 in), install a new balancer unit.
    • Using the backlash measurement, select the proper shims from the Adjustment Shim Selection Table.
    • Remove the balancer unit from the cylinder block.
    • Install the selected adjustment shims on the seat faces of the balancer unit.
      Fig 1: Adjustment Shim Selection Chart
      G09599756Courtesy of FORD MOTOR CO.
  12. Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC  Timing Peg. The engine is now at TDC  .

    Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC  .

    G09599757
  13. With the balancer unit shaft marks at the TDC  position, slowly install the balancer unit to the cylinder block to avoid interference between the crankshaft drive gear and the balancer unit driven gear.
    G09599758
  14. Torque  :

    Stage 1: 18 lb.ft (25 Nm)

    Stage 2: 31 lb.ft (42 Nm)

    G09599759
  15. NOTE: Measure the backlash and verify that it is within specified range at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. It will be necessary to reset the measuring equipment between measurements.
    NOTE: The measurement must be taken with the Dial Indicator Gauge with Holding Fixture, a 5-mm Allen wrench and worm clamp set up as shown in illustration below. Mark the Allen wrench with a file 80 mm (3.149 in) above the driven gear shaft center. Make sure the worm clamp and Allen wrench are not touching the balance shaft housing.
    NOTE: For an accurate measurement while measuring the gear backlash, insert a screwdriver as shown in illustration below, into the crankshaft No. 1 crankweight area and set both the rotation and the thrust direction with the screwdriver, using a prying action as shown in illustration below.
    • Position as shown in illustration below. Measure the gear backlash.

      Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge  .

    • Position the Dial Indicator Gauge with Holding Fixture (1) on the Allen wrench 80 mm (3.149 in) above the driven gear shaft center (2) on the balancer unit.
    • Rotate the crankshaft clockwise and measure the backlash at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees.
    • If the backlash exceeds the specified range of 0.020 to 0.120 mm (0.00078 to 0.0047 in), install a new balancer unit and repeat the procedure.
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