51-75

51. To decrease the backlash, install a thicker differential bearing shim and a thinner differential bearing shim as shown.





52. Liberally lubricate the axle shaft shift lever, and install a new O-ring.
- Use Ford Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or equivalent meeting Ford specification ESE-MIC171-A.





53. install the axle shaft shift lever. Position the clutch fork.
- Install the axle shaft shift lever.
- Align the manual shaft retaining pin holes.





54. Install the manual shaft retaining pin flush with the axle shaft shift lever.





55. Lift the axle shaft shift lever, and position the coupler shift selector gear, tapered end downward, into the clutch fork.





56. Using the special tools, install the pilot bearing assembly into the axle cluster gear shaft.





57. Insert the axle cluster gear shaft through the coupler shift selector gear and engage the splines.





58. Coat the thrust washer with grease, and position it on the axle cluster gear shaft.
- Use Premium Long Life Grease XG-l-C or equivalent meeting Ford specification ESA-MIC75-B.





59. CAUTION: Remove all of the old liquid gasket, and make sure the machined surfaces are free of oil before applying the new silicone rubber.

CAUTION: Install the axle housing tube within 15 minutes of applying the silicone, or it will be necessary to remove and reapply new sealant. If possible, allow one hour before filling with lubricant to make sure the silicone has cured.

CAUTION: Do not allow any silicone rubber to squeeze inside during assembly.

Fill the groove with Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4.





60. Assemble the axle housing tube.
- Align the bolt holes and position the axle housing tube.
- Position the axle identification tag.
- Install the bolts.





61. Examine the axle shaft seal and bearing surface for damage. If necessary, polish the bearing surface with fine crocus cloth.





62. Insert the axle shaft and engage it with the side gear-





63. NOTE: Do not reuse the old snap ring.

Push in on the axle shaft and install a new snap ring-





64. Install the clutch shaft rod boot.
1 Fully extend the actuator motor shaft and plug the vacuum ports.
2 Position the front axle actuator motor assembly.
3 Install the clutch shaft rod boot.





65. With the actuator motor shaft fully extended and the vacuum ports plugged, engage the shift lever.





66. Seat the front axle actuator motor assembly and install the E-ring.





67. Seat the clutch shaft rod boot in the slot in the actuator housing.
- Remove the plugs from the vacuum ports.





68. NOTE: Install a new vacuum motor if any vacuum leakage is observed.

NOTE: With the lever moved outboard, the axle is engaged and the axles will turn opposite of each other. With the lever moved inboard, the axle is disengaged and the axles will turn freely of each other.

Verify the front axle actuator motor assembly operation (engage).
- Using the special tool, apply vacuum to the outer vacuum port to move the shift lever outboard. Rotate one axle shaft to verify engagement.





69. Verify the front axle actuator motor assembly operation (disengage).
- Using the special tool, apply vacuum to the inner vacuum port to move the shift lever inboard. Rotate one axle to verify disengagement.
70. Remove the axle assembly from the Holding Fixture and place it on the bench.





71. CAUTION: Remove all of the oil liquid gasket, and make sure the machined surfaces are free of oil before applying the new silicone rubber.

CAUTION: Install the differential housing cover within 15 minutes of applying the silicone, or it will be necessary to remove and reapply new sealant. If possible, allow one hour before filling with lubricant to make sure the silicone has cured.

Fill the sealing groove on the differential housing cover with Silicone Gasket and Sealant F7AZ- 19554-EA or equivalent meeting Ford specification WSE-M4G323-A4.





72. Install the differential housing cover.
1 Position the differential housing cover.
2 Install the bolts.





73. Fill the differential carrier housing, and install the fill plug.
- Use Motorcraft SAE 75W-90 Premium 4x4 Front Axle Lubricant XY-75W90-TQL or equivalent meeting Ford specification WSP-M2C201-A.
- Be sure to tighten both the drain and fill plugs.
74. Install the vacuum control shield.
- Install the shield.
- Install the bolts and the torque bolts.
75. Install the front drive axle assembly.