Differential Ring And Pinion

Differential Ring And Pinion

























Removal

1. Remove the axle assembly. For additional information, refer to Axle Assembly Axle Assembly.

2. Drain the front axle assembly.

1. Remove the 10 differential housing cover bolts.

2. Remove the differential cover.





3. Install the Adapters on the differential housing.





4. Install the Transmission Holding Fixture on the Adapters and mount the assembly to a bench.





5. Remove the 2 differential bearing caps.

1. Remove the 4 differential bearing cap bolts.

2. Remove and identify the 2 differential bearing caps.





6. Install the Differential Carrier Spreader, Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge.





7. NOTICE: Overspreading can damage the differential housing.

Spread the differential housing to the specification.

1. Adjust the Dial Indicator to zero.

2. Tighten the differential carrier spreader screw.

3. Remove the Dial Indicator.





8. NOTICE: Use wood blocks to avoid damaging the differential housing.

Remove the differential assembly from the housing.

1. Position the wood blocks.

2. Push downward on the pry bars.

3. Remove the differential assembly.

4. Remove the Differential Carrier Spreader.





9. Remove and discard the 10 differential ring gear bolts and the differential ring gear.
- Use a drift punch to separate the differential ring gear from the differential case.





10. Assemble the Drive Pinion/Differential Carrier Puller.





11. Position the Drive Pinion/Differential Carrier Puller on the differential bearing.





12. Using the Drive Pinion/Differential Carrier Puller, remove and discard the LH and RH differential bearings.





13. Using the Drive Pinion Flange Holding Fixture to hold the pinion flange, remove and discard the pinion nut.





14. Using the 2-Jaw Puller, remove the pinion flange.





15. Using a soft-face hammer, remove the pinion from the differential housing.

1. Hold the pinion inside the differential housing.

2. Use a soft-face hammer to remove the pinion from the outer pinion bearing.





16. Using gripping pliers and a hammer, remove and discard the drive pinion oil seal.





17. Remove the front axle drive pinion shaft oil slinger and the outer pinion bearing.
- Discard the outer pinion bearing.





18. NOTE: To prevent it from becoming misaligned in the bore, remove the outer pinion bearing cup by tapping alternately on each side of the outer pinion bearing cup with a brass drift.

Remove and discard the outer pinion bearing cup.





19. NOTE: To prevent it from becoming misaligned in the bore, remove the inner pinion bearing cup by tapping alternately on each side of the inner pinion bearing cup with a brass drift.

Remove and discard the inner pinion bearing cup.





Installation

1. Install new drive pinion bearing cups.
- Using the Rear Axle Draw Bar, Drive Pinion Bearing Cup Installers install the drive pinion bearing cups.





2. Assemble and position the following in the differential housing.

1. Position the Adapter.

2. Position the Adapter.

3. Position the inner pinion bearing.

4. Position the Gauge Disc.

5. Position the Adapter.

6. Position the outer pinion bearing.

7. Thread on the Adapter.





3. Using a Nm torque wrench, tighten the Adapter.
- Tighten to 2.5 Nm (22 lb-in).





4. NOTE: Offset the Adapter to obtain an accurate reading.

Rotate the Adapter several half turns to make sure the pinion bearings seat correctly. Position the Adapter as shown.





5. Install the Gauge Tube.

1. Position the Gauge Tube.

2. Install the 2 differential bearing caps.

3. Install the 4 differential bearing cap bolts.
- Tighten to 61 Nm (45 lb-ft).





6. NOTE: Selection of a drive pinion position shim that is too thick results in deep tooth contact at final assembly. Do not attempt to force the feeler gauge or drive pinion position shim between the Adapter and the Gauge Tube. A slight drag indicates a correct selection.

Using a feeler gauge or a flat, clean drive pinion position shim, measure between the Adapter and the Gauge Tube. Record the measurement.





7. Select the correct thickness drive pinion position shim.
- New drive pinion position shims are available in the following sizes:






- Notice the plus (+), minus (-) or zero (0) etching on the new drive pinion, and adjust the thickness of the new drive pinion position shim. If etching is plus (+), subtract the number from the gauged drive pinion position shim thickness. If etching is minus (-), add the number to the gauged drive pinion position shim thickness.





8. Install the selected drive pinion position shim and the new inner pinion bearing.
- Using the Drive Pinion Bearing Cone Installer and a suitable press, seat the inner pinion bearing firmly against the drive pinion position shim.





9. Install a new collapsible spacer.





10. Install the new outer drive pinion bearing and the drive pinion oil slinger.





11. NOTE: Lubricate the drive pinion oil seal lips with rear axle lubricant.

Using the Drive Pinion Oil Seal Installer, install the drive pinion oil seal.





12. Lubricate the drive pinion gear splines with rear axle lubricant.

13. Install the drive pinion gear into the axle housing.





14. NOTICE: Never use a metal hammer on the pinion flange or install the flange with power tools or damage to the component may occur.

Position the pinion flange.





15. Using the Drive Pinion Flange Installer, install the pinion flange.





16. NOTICE: Do not loosen the pinion nut to reduce pinion bearing preload. Install a new collapsible spacer and pinion nut if pinion bearing preload reduction is necessary or damage to the component may occur.

Using the Drive Pinion Flange Holding Fixture to hold the pinion flange, tighten the new pinion nut to set the pinion bearing preload.

- Tighten the pinion nut, rotating the pinion occasionally to make sure the pinion bearings are seating correctly. Take frequent pinion bearing preload readings by rotating the pinion with a Nm torque wrench. The final reading must be 1.7-3.4 Nm (15-30 lb-in).





17. Install the Differential Dummy Bearing Gauge.





18. Position the differential assembly and Differential Dummy Bearing Gauge in the differential housing.





19. NOTE: Repeat this step until obtaining a consistent reading.

Measure the total differential end play.

1. Install the Dial Indicator Gauge with Holding Tool.

2. Force the differential assembly as far as possible away from the indicator. Position the indicator tip on the machined surface and adjust it to measure full travel. With force still applied, set the indicator to zero.

3. Force the differential assembly as far as possible in the opposite direction.

4. Record the total end play reading on the Differential Bearing Shim Selection Procedure Worksheet, Line A in this procedure.





20. Remove the Dial Indicator Gauge with Holding Fixture, then remove the differential assembly.

1. Remove the Dial Indicator Gauge with Holding Fixture.

2. Remove the differential assembly.





21. NOTICE: Do not reuse the original differential ring gear bolts.

Using a suitable press, install the differential ring gear.

1. Position the differential ring gear and the differential assembly. Start 3 new differential ring gear bolts to align the holes in the differential ring gear and the differential assembly.

2. Using a suitable press, install the differential ring gear.





22. Install the remaining 7 new differential ring gear bolts.
- Tighten to 122 Nm (90 lb-ft).





23. Install the special tools and position the differential assembly in the differential housing.

1. Install the Differential Dummy Bearing Gauge.

2. Position the differential assembly in the differential housing.





24. Position the Dial Indicator Gauge with Holding Fixture.





25. Force the differential ring gear into mesh with the pinion gear (zero backlash). With force still applied, set the Dial Indicator to zero.





26. Force the differential ring gear away from the pinion gear as far as possible. Record the reading on the Differential Bearing Shim Selection Procedure Worksheet, Line D in this procedure.





27. Remove the Dial Indicator Gauge with Holding Fixture.





28. Remove the differential assembly from the differential housing. Remove the Differential Dummy Bearing Gauge from the differential assembly hubs.





29. Complete the worksheet and select the appropriate thickness differential bearing shims. New differential bearing shims are available in 0.0762 mm (0.003 in), 0.127 mm (0.005 in), 0.254 mm (0.010 in) and 0.762 mm (0.030 in) thickness.






30. Install the selected differential bearing shims and the RH and LH differential bearings.

1. Position the differential bearing shims and the differential bearing.

2. Using a suitable press, install the differential bearing.

- Repeat this step for opposite side of the differential assembly.

- Most axles will have the larger amount of shims on the differential ring gear side and the smaller amount on the case side.





31. Install the Dial Indicator Gauge with Holding Fixture, Clutch Housing Gauge and Differential Carrier Spreader.
- Position the clutch housing gauge needle in the differential carrier spreader adapter hole.





32. NOTICE: Overspreading can damage the differential housing.

Spread the differential housing to the specification.





33. Remove the Dial Indicator Gauge with Holding Fixture and the Clutch Housing Gauge.





34. NOTE: Push the differential assembly downward to fully seat the differential bearing cups in the differential housing.

Install the 2 differential bearing cups and the differential assembly in the differential housing.

1. Position the 2 differential bearing cups on the differential bearings.

2. Lower the differential assembly in place.





35. NOTE: Do not tighten the differential bearing cap bolts to specification at this time.

Install the 2 differential bearing caps in their original positions.

1. Position the 2 differential bearing caps.

2. Install the 4 differential bearing cap bolts hand-tight.





36. Remove the axle spreader.

37. Tighten the 4 differential bearing cap bolts.
- Tighten to 61 Nm (45 lb-ft).





38. Verify that the differential assembly rotates freely.

39. Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, measure the backlash at 3 equally spaced points on the differential ring gear.

1. Mount the Dial Indicator Gauge with Holding Fixture.

2. Position the Clutch Housing Gauge.

3. Zero the indicator.

4. Turn the differential ring gear without turning the pinion gear. Record the measurement.

- The backlash tolerance is 0.13 mm (0.005 in) to 0.20 mm (0.008 in) and cannot vary more than 0.05 mm (0.002 in) between points checked.

- If the backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness of the other differential bearing shim by the same amount.





40. Remove the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge.





41. Apply marking compound and rotate the differential assembly 5 complete revolutions.

42. Verify an acceptable pattern check.

43. Install the RH axle shaft.

44. NOTE: The machined surfaces on the differential housing and the differential housing cover must be clean and free of oil before applying the new silicone sealant. Cover the inside of the axle before cleaning the machined surface to prevent contamination.

NOTE: Install the differential housing cover within 15 minutes of applying the silicone material.

NOTE: Allow the sealant to cure for 1 hour before filling the axle with lubricant.

Apply a continuous bead of sealant, of the specified thickness, to the differential housing cover mounting surface.





45. Install the differential housing cover and the 10 differential housing cover bolts.
- Tighten to 29 Nm (21 lb-ft).

46. Install the axle assembly. For additional information, refer to Axle Assembly Axle Assembly.

47. Remove the fill plug and fill the axle with Motorcraft 80W-90 Premium Rear Axle Lubricant to 9.56 mm (0.38 in) below the bottom of the filler hole.

48. Install the fill plug.
- Tighten to 27 Nm (20 lb-ft).