After Disassembly

DESCRIPTION
Thoroughly clean all parts. Always use new solvent when cleaning bearings. Do not spin dry bearings with compressed air. Oil the bearings immediately with SAE 80W-90; Premium Rear Axle Lubricant XY-80W90-QL or -KL or equivalent meeting Ford specification WSP-M2C197-A to prevent rusting. Inspect parts for damage. Clean the inside of rear axle housing before rebuilding. When a scored or chipped gearset is replaced, the rear axle housing must be washed thoroughly. Inspections of individual parts are described as follows:

GEARS
- Examine differential ring gear and pinion teeth for scoring, excessive wear, nicks and chipping. Worn scored and damaged differential ring gear and pinions cannot be rebuilt to correct a noisy condition.
- Pattern inspection allows the technician to detect gross errors in set-up prior to complete assembly. Pattern contact should be within the primary area of the ring gear tooth surface, avoiding narrow or hard contact with the outer perimeter of tooth (top to root, toe to heel). Pattern inspection should be on the drive (pull) side. Correct assembly of drive pattern will result in satisfactory coast performance. If gross pattern error is detected, with preferred backlash 0.305 to 0.381 mm (0.012 to 0.015 inch), check pinion shim selection.

BEARING CUPS
Check differential drive pinion bearing cups for deep scores, galling or spelling. If a 0.038-mm (0.0015-inch) feeler gauge can be inserted between a differential drive pinion bearing cup and the bottom of its bore at any point around the differential drive pinion bearing cup, the differential drive pinion bearing cup must be reseated.

UNIVERSAL JOINT FLANGE, REAR AXLE
Make sure surfaces of the rear axle universal joint flange were not damaged when it was removed from the pinion. The end of the rear axle universal joint flange that contacts bearing cone as well as the nut counterbore and seal surface must be smooth and free of nicks.

CONE AND ROLLER ASSEMBLIES
When operated in the differential drive pinion bearing cups, bearing rollers must turn without roughness. Examine the rollers for wear (pitting, scoring, galling or spelling). If inspection reveals either a damaged differential drive pinion bearing cup or a damaged differential pinion bearing, replace both parts.

CARRIER HOUSING
Make sure the differential bearing bores are smooth. Remove any nicks or burrs from the mounting surfaces of the rear axle housing.

DIFFERENTIAL CASE
Make sure the hubs where the differential bearings mount are smooth. Carefully examine the differential case bearing shoulders which may have been damaged when the differential bearings were removed. The differential bearing assemblies will fail if they do not seat firmly against the shoulders. Check the fit (free rotation) of the axle shaft in their counterbores.