Part 1 of 2

1. If baffle was removed, position the baffle on Differential Bearing Cone Replacer.

CAUTION: Do not omit baffle because bearing failure may result.





2. Use Differential Bearing Cone Replacer to install the baffle.





3. Oil the new pinion bearing cups with Motorcraft SAE 75W90 4x4 Axle Lubricant XY-75W90-QL meeting Ford specification WSP-M2C201-A or equivalent and install.
- Use Pinion Bearing Cup Replacer to install the bearing cups.

NOTE: Whenever the front pinion bearing cups are replaced, the differential pinion bearing must be replaced.





4. Assemble and position Pinion Depth Gauge Set.
(1) Position Screw.
(2) Position Aligning Adapter.
(3) Position Gauge Disc.
(4) Position Gauge Block.
(5) Position the differential pinion bearing.
(6) Position the differential pinion bearing.
(7) Thread on Driver Handle.

NOTE: Apply only a light oil film on the pinion bearings before performing this measurement.





5. Tighten Driver Handle.





6. Rotate the gauge block several half turns to ensure proper seating of the pinion bearings, and position the gauge block.

NOTE: The gauge block must be offset to obtain an accurate reading.





7. Install Gauge Tube.
(1) Position the gauge tube and paper shipping tags.
(2) Install the differential bearing caps.
(3) Install the bolts.





8. Use a drive pinion bearing adjustment shim as a gauge for shim selection.
- The pinion bearing adjustment shim is checked between the gauge block and the gauge tube.

NOTE:
- Drive pinion bearing adjustment shims must be flat and clean.
- A slight drag should be felt for correct shim selection. Do not attempt to force the pinion shim between the gauge block and the gauge tube. This will minimize selection of a pinion shim thicker than required, which results in a deep tooth contact in final assembly of integrate rear axle assemblies.





9. Install the pinion bearing.
(1) Place the drive pinion bearing adjustment shim on the pinion.
(2) Using a (A) press and (B) Pinion Bearing Cone Replacer, press the differential pinion bearing until it is firmly seated on the pinion.

NOTE: The same pinion bearing used in this procedure must be used in final axle assembly.





10. Place a new differential drive pinion collapsible spacer on the pinion stem.





11. Install the differential pinion bearing and differential pinion seal.
(1) Position the differential pinion bearing.
(2) Position the front axle drive pinion shaft oil slinger.
(3) Position the differential pinion seal.
(4) Use Pinion Seal Replacer to install the differential pinion seal.





12. Position the pinion gear.
(1) Apply a small amount of Motorcraft SAE 75W90 4x4 Axle Lubricant XY-75W90-QL or equivalent meeting Ford specification WSP-M2C201-A to the pinion gear splines.
(2) Position the pinion gear.





13. Align the index marks and position the universal joint flange onto the pinion shaft.

CAUTION: The universal joint flange must never be hammered on or installed with power tools.





14. Using Companion Flange Replacer, install the front axle universal joint flange.

NOTE: Rotate the pinion occasionally to ensure proper differential pinion bearing seating.





15. Apply a small amount of lubricant to the washer side of the new pinion nut and install the nut.





16. Tighten the pinion nut.
(1) Position (A) Companion Flange Holding Tool install two (B) companion flange holding tool bolts.
(2) Tighten the pinion nut.

NOTE: Never back off the pinion nut to reduce preload. If reduced preload is required, a new differential drive pinion collapsible spacer and pinion nut must be installed. Take frequent differential pinion bearing torque preload readings until the specified preload reading is obtained.

CAUTION: Use extreme care not to damage the aluminum front axle housing while performing these procedures.





17. Install Master Bearing (LH) and Master Bearing (RH) on the differential case.

CAUTION: Master bearings are marked LH and RH and must be installed as shown.





18. Install the differential case with master bearings into the front axle housing.





19. Measure the total end play.
(1) Position (A) Dial Indicator Bracketry and (By Dial Indicator.
(2) Position indicator tip on machined surface and adjust to measure full travel.
(3) Push the differential case left and right (as far as possible).





(4) Measure the total end play and record reading on the Differential Bearing Shim Selection Procedure Worksheet Line A.

NOTE: Repeat this step until a consistent reading is obtained.





20. Remove the differential case.
(1) Remove Dial Indicator Bracketry and Dial Indicator.
(2) Remove the differential case.





21. Use a fine flat file to remove any burrs or nicks from the differential ring gear and pinion mounting surface.





22. Install the ring gear.
(1) Position and then start three (C) ring gear bolts to align the holes in the (A) ring gear and the (B) differential case.
(2) Use an appropriate press to install the ring gear.





23. Install the remaining ring gear bolts.





24. Remove the three ring gear bolts.





25. Position the differential case.
(1) Install (A) Master Bearing (LH) and (B) Master Bearing (RH) on the (C) differential case.
(2) Position the differential case in the front axle housing with the three missing bolts positioned down.





26. Position (A) Dial Indicator Bracketry and (B) Dial Indicator.





27. Push and rock the ring gear into mesh with the pinion gear (zero backlash) and set Dial Indicator at zero.









28. Move the ring gear away from the pinion gear as far as possible and record the reading on the drive Pinion Bearing Adjustment Shim Selection Procedure Worksheet Line B.





29. Remove (A) Dial Indicator and (B) Dial Indicator Bracketry.





30. Remove the (A) differential case, (B) Master Bearing (LH) and (C) Master Bearing (RH).





31. Clamp Bearing Preload Tool base in a soft jawed vise with bearing mounting surface above the surface of the vise.

NOTE:
- Both differential bearing stand heights must be measured prior to installation on the differential case.
- Mark left and right differential bearings before measuring.





32. Position the (A) differential bearing assembly in (B) Bearing Preload Tool and tighten the tool.





33. Measure differential bearing stand height.
(1) Invert Bearing Preload Tool and bearing assembly in the vise.
(2) Use a depth micrometer to measure and record the differential bearing stand height.
- Repeat the procedure for the other bearing.











34. Select appropriate differential bearings.