Differential Bearings

Differential Bearings

Special Tool(s):

Material:

Removal
1. Remove the differential carrier.
2. Remove the differential bearings with the special tools.

3. Index-mark the driveshaft flange and pinion flange for correct alignment during installation.

4. Remove the 4 driveshaft flange bolts.

5. CAUTION: The driveshaft centering socket yoke fits tightly on the pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft centering socket yoke from the pinion flange. Pry only in the area shown with a suitable tool to disconnect the driveshaft centering socket yoke from the pinion flange.

Using a suitable tool as shown, disconnect the driveshaft centering socket yoke from the pinion flange.
^ Using mechanic's wire, position the driveshaft aside.

6. Using the special tool to hold the pinion flange, remove and discard the pinion nut.

7. Index-mark the pinion flange in relation to the drive pinion stem to make sure of correct alignment during installation.

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

9. Force up on the metal flange of the drive pinion seal. Install gripping pliers and strike with a hammer until the drive pinion seal is removed.

10. Remove the drive pinion shaft oil slinger and the outer drive pinion bearing.

11. Install the special tool, then use a soft-faced hammer to drive the pinion gear out of the outer drive pinion bearing and remove the pinion gear.

12. Remove and discard the drive pinion collapsible spacer.

13. Using the special tool, remove the drive pinion bearing and spacer.

14. Using a brass drift, remove the drive pinion bearing cups by tapping alternately on opposite sides of the drive pinion bearing cups.

Installation

All vehicles
1. Measure and record the stack height of the new inner pinion bearing and cup.
2. Position the special tools and the inner and outer drive pinion bearing cups in their respective bores.
1 After placing the inner and outer drive pinion bearing cups in their bores, place the special tool on the inner drive pinion bearing cup.
2 Place the special tool on the outer drive pinion bearing cup.
3 Install the special tools.

3. Tighten the special tool to seat the drive pinion bearing cups into their bores.

4. Make sure the drive pinion bearing cups are correctly seated in their bores.
^ If a feeler gauge of the specification shown in the illustration can be inserted between a drive pinion bearing cup and the bottom of its bore at any point around the drive pinion bearing cup, the drive pinion bearing cup is not correctly seated.

Vehicles with a 38.1 mm (1.5 inch) stack height inner pinion bearing

5. CAUTION: The special tools must be used with the new pinion bearings to be used.

NOTE: Install new drive pinion bearings without any additional lubricant since the anti-rust oil provides adequate lubricant without upsetting the drive pinion bearing preload settings.

Install the special tools.

Vehicles with a 31.75 mm (1.25 inch) stack height inner pinion bearing

6. CAUTION: The special tools must be used with the new pinion bearings to be used.

NOTE: Install new drive pinion bearings without any additional lubricant since the anti-rust oil provides adequate lubricant without upsetting the drive pinion bearing preload settings.

Install the special tools.

All vehicles
7. Tighten the special tool to the specified rotational torque.
^ Tighten to 2.2 Nm (20 inch lbs.).

8. NOTE: The special tool must be offset to obtain an accurate reading.

Rotate the special tool several half-turns to make sure of correct seating of the drive pinion bearings, then position the special tool.

9. Install the special tool.
1 Position the special tool.
2 Install the differential side bearing caps.
3 Install the differential side bearing cap bolts.

10. NOTE: Drive pinion bearing adjustment shims must be flat and clean.

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

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

11. Remove the pinion depth gauge set from the axle housing.
12. Using a press and the special tools, press the pinion bearing until it is firmly seated on the pinion gear and the drive pinion bearing adjustment shim.

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

14. Install the outer drive pinion bearing and drive pinion shaft oil slinger.

15. Lubricate the new drive pinion seal with grease.

16. CAUTION: If the new drive pinion seal becomes misaligned during installation, remove the drive pinion seal and install a new drive pinion seal.

Using the special tool, install a new drive pinion seal.

17. Install the pinion gear in the pinion gear bore from inside the axle housing.

18. Using the special tool, install the pinion flange.

19. Position the new pinion nut.

20. CAUTION: Under no circumstances is the pinion nut to be backed off to reduce drive pinion bearing preload. If reduced drive pinion bearing preload is required, a new drive pinion collapsible spacer and pinion nut must be installed.

CAUTION: Remove the special tool while taking drive pinion bearing preload readings with the Nm (inch lbs.) torque wrench.

Using the special tool to hold the pinion flange, tighten the pinion nut.
^ Rotate the drive pinion occasionally to make sure the drive pinion bearings are seating correctly.
^ Install a Nm (inch lbs.) torque wrench on the pinion nut.
^ Rotating the drive pinion through several revolutions, take frequent drive pinion bearing preload readings until the original recorded drive pinion bearing preload reading is obtained.

21. Using the special tool, install the differential bearings.

22. Install the differential assembly in the axle housing.

23. NOTE: Differential bearing shims are to be installed with the chamfer facing outboard.

Install a differential bearing shim on the LH side.

24. CAUTION: Index-mark the position of the differential bearing caps as arrows may not be visible. The differential bearing caps must be installed in their original locations and positions.

NOTE: Apply pressure toward the LH side to make sure the LH differential bearing cap is seated.

Install the LH differential bearing cap and loosely install the differential bearing cap bolts.

25. Install progressively larger differential bearing shims on the RH side until the largest differential bearing shim selected that can be installed by hand.

26. Install the RH side differential bearing cap and tighten the LH side and RH side differential bearing cap bolts.
^ Tighten to 105 Nm (77 ft. lbs.).

27. Rotate the differential assembly to make sure it rotates freely.

28. NOTE: If ring gear backlash is within specification, go to Step 32.

Using the special tools, measure ring gear backlash.
^ Turn the ring gear without turning the pinion gear and record the measurement.

29. NOTE: The differential bearing caps must be removed before differential bearing shims can be installed.

To increase ring gear backlash, install a thicker differential bearing shim and a thinner differential bearing shim as shown.
^ If ring gear backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness on the other differential bearing shim by the same amount.

30. Rotate the differential assembly several times to make sure the differential bearings are seated.

31. Using the special tools, recheck the ring gear backlash.

32. Remove the differential bearing cap bolts and differential bearing caps.

33. NOTE: Differential bearing shims are to be installed with the chamfer facing outboard.

NOTE: To establish differential bearing preload, increase both left and right differential bearing shim sizes as shown. Make sure differential bearing shims are fully seated and the differential assembly turns freely.

Using the special tool, install the differential bearing shims.

34. Install the differential bearing caps and differential bearing cap bolts.
^ Tighten to 105 Nm (77 ft. lbs.).

35. Apply Motorcraft High Contrast Hypoid Gear Marking Compound and rotate the differential assembly 5 complete revolutions.
36. Verify an acceptable pattern check.
37. Install the axle shafts.
38. Position the driveshaft and align the index mark on the pinion flange.

39. CAUTION: The driveshaft centering socket yoke fits tightly on the pinion flange pilot. To make sure that the driveshaft centering socket yoke seats squarely on the pinion flange, tighten the driveshaft flange bolts evenly in a cross pattern.

Install the driveshaft flange bolts.
^ Tighten to 103 Nm (76 ft. lbs.).

REMOVAL AND INSTALLATION

Axle Assembly

Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the disc brake caliper bolts and the disc brake caliper.
^ Using mechanic's wire, position aside the disc brake caliper.
^ To install, tighten to 30 Nm (22 ft. lbs.).

3. Index-mark the driveshaft flange and pinion flange for correct alignment during installation.

4. Remove the 4 driveshaft flange bolts.

6. Disconnect the disc brake anti-lock sensor from the axle.

NOTE: If the vent hose is disconnected from the vehicle body, a new retainer must be installed.

7. Remove the vent hose.

8. Remove the brake hose junction block bolt.
^ To install, tighten to 18 Nm (13 ft. lbs.).

9. Separate the parking brake cables from the axle housing.
^ To install, tighten to 25 Nm (18 ft. lbs.).

10. Remove the brake line bracket bolt, then remove the brake line from the brake line retaining clips.
^ To install, tighten to 25 Nm (18 ft. lbs.).

11. Remove the parking brake cables.

12. Support the axle with a suitable transmission jack.

13. Remove the lower shock absorber nuts and bolts.
^ To install, tighten to 90 Nm (66 ft. lbs.).

14. Remove the rear axle U-bolt assembly.
1 Remove the spring plate nuts.
2 Remove the 2 spring plate U-bolts.
3 Remove the spring plate.
4 Repeat the procedure for the other side.
^ To install, tighten to 115 Nm (85 ft. lbs.).

15. Lower the axle housing from the vehicle.
16. To install the original assembly, reverse the removal procedure.
17. To install a factory replacement axle assembly, remove the new disc brake calipers and the vent plug. Follow the removal procedure in reverse.
18. Check the rear axle fluid level after installation.