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Differential Assembly: Reassembly

  1. If new components have been installed, proper gear set assembly must be checked using Pinion Depth Gauge (T79P-4020-A) to determine correct pinion shim thickness. See PINION DEPTH  under ADJUSTMENTS.
  2. Using Pinion Bearing Cup Installer (T71P-4616-A), install new bearing cups in housing. Bearing cups must be seated in bores so a .0015" (.038 mm) feeler gauge will not fit between bearing cup and bottom of bore.
  3. Install necessary shims on pinion to obtain correct pinion depth. Using Bearing Cone Replacer (T53T-4621-C), press rear bearing on pinion shaft. Ensure bearing is seated against shims. Lubricate pinion bearings with gear lubricant. Install pinion in housing. Install NEW collapsible spacer and front pinion bearing. See Fig 1 .
  4. Ensure sealing surfaces are clean and free of burrs. Using Seal Installer (T79P-4676-A), install NEW pinion oil seal. If oil seal becomes cocked during installation, remove and replace seal. Lubricate oil seal lips with Lubricant (XG-1-C).
    5. CAUTION: DO NOT hammer or use power tools on companion flange.
  5. Check pinion and companion flange splines for burrs. Coat companion flange splines with small amount of gear lubricant. Align marks on companion flange and pinion (used pinion only). Install companion flange on pinion. Coat washer side of NEW pinion nut with gear lubricant, and install nut.
    6. NOTE: If desired preload is exceeded, install new collapsible spacer, and retighten new pinion nut until proper preload is obtained.
  6. Using Companion Flange Holder (T78P-4851-A), hold companion flange and gradually tighten nut to obtain correct pinion bearing preload. See PINION BEARING PRELOAD  under ADJUSTMENTS.
  7. Lubricate all parts with gear lubricant. Place side gears and thrust washers into differential case. Place pinion gears and thrust washers exactly opposite each other in differential case openings, and mesh pinion gears with side gears.
  8. Install ring gear with new mounting bolts. Apply Loctite to threads and tighten bolts to proper specification. See TORQUE SPECIFICATIONS  . Press new bearings onto differential case using properly sized sleeve. Ensure bearings are fully seated.
  9. After proper shims have been chosen to obtain proper ring gear backlash and bearing preload, differential assembly may be installed. See DIFFERENTIAL BEARING PRELOAD & RING GEAR BACKLASH  under ADJUSTMENTS.
  10. Install differential assembly and bearing cups into housing. Install differential bearing caps and bolts. Tighten differential bearing cap bolts to specification. See TORQUE SPECIFICATIONS  .
  11. Check ring gear backlash and gear tooth contact pattern. See GEAR TOOTH CONTACT PATTERN article in GENERAL INFORMATION. Check gear tooth contact pattern before final assembly. Pinion depth and ring gear backlash may be adjusted to obtain proper gear tooth contact pattern. When all adjustments are correct, install cover. To install housing assembly in vehicle, reverse removal procedure.
Fig 1: Exploded View Of Differential Assembly
G90J13598Courtesy of FORD MOTOR CO.
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