Assembly
DRIVE PINION SHIM SELECTIONPerform Drive Pinion Shim Selection procedure before begining assembly. Adjustments
PINION BEARING & CUP INSTALLATION
1. Place the drive pinion bearing adjustment shims on the pinion. Press the pinion bearing cone and roller assembly until it is firmly seated on the pinion with Pinion Bearing Cone Replacer T53T-4621-C.
NOTE: The same differential pinion bearing used in this procedure must be used in final assembly of the axle.
2. Make sure splines on pinion stem are free of burrs. If burrs are evident, remove using a fine crocus cloth, working in a rotational motion. Wipe pinion clean.
3. Install the new differential bearing cups with Pinion Bearing Cup Replacer T71P-4616-A. Make sure the differential bearing cups are properly seated in their bores. If a 0.038 mm (0.0015-inch) feeler gauge can be inserted between a differential bearing cup and the bottom of its bore at any point around the differential bearing cup, the differential bearing cup is not properly seated. Whenever the differential bearing cups are replaced, the differential pinion bearing should also be replaced.
NOTE:
- Do not remove the differential pinion bearings from the carrier casting unless the differential pinion bearings are damaged.
- To make sure bearings are seated properly, clean bores before installing differential pinion bearings.
DRIVE PINION SEAL INSTALLATION
CAUTION: Installation without the proper tool may result in early flange yoke seal failure. If rear axle drive pinion seal becomes cocked during installation, remove it and install new one.
NOTE: Clean the differential pinion bearing surface before installing the rear axle drive pinion seal in the housing bore. Coat lips of rear axle drive pinion seal with Premium Long-Life Grease XG-1-C, -K or equivalent meeting Ford specification ESA-M1C75-B.
1. Install the front differential pinion bearing and drive pinion oil seal deflector in the housing bore and install the rear axle drive pinion seal on the Pinion Seal Replacer T79P-4676-A.
2. Install rear axle drive pinion seal in rear axle housing.
3. From rear of rear axle housing, install drive pinion assembly (drive pinion, drive pinion bearing adjustment shims, rear differential pinion bearing and differential drive pinion collapsible spacer) into the rear axle housing shaft bore.
UNIVERSAL JOINT FLANGE INSTALLATION
1. Apply a small amount of SAE 80W-90; Premium Rear Axle Lubricant XY-80W90-QL or -KL or equivalent meeting Ford specification WSP-M2C197-A to rear axle universal joint flange splines.
2. Align mark on rear axle universal joint flange with mark on the pinion shaft.
NOTE: If installing a new rear axle universal joint flange, disregard the scribe mark on the pinion stem.
3. With drive pinion in place in rear axle housing, install rear axle universal joint flange using Companion Flange Replacer TOOL-4858-E or equivalent.
CAUTION: The circular rear axle universal joint flange must never be hammered on or installed with power tools.
4. Install a new pinion nut on pinion shaft (apply a small amount of lubricant on the washer side of nut).
5. Hold the rear axle universal joint flange with Companion Flange Holding Tool T78P-4851-A while tightening the nut.
6. Tighten pinion nut. Rotate pinion occasionally to make sure differential pinion bearing is properly seated. Take frequent pinion bearing torque preload readings until obtaining the original recorded preload reading.
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.
7. If the original recorded preload is less than specification, tighten used differential pinion bearing to 0.9-1.6 Nm (8-14 in. lbs.) and new differential pinion bearings to 1.8-3.2 Nm (16-29 in. lbs.). If the preload is higher than specification tighten to original reading as recorded.
DIFFERENTIAL CASE INSTALLATION
Perform Differential Case Installation procedure. Service and Repair
COVER INSTALLATION
1. Clean sealing surfaces and groove in axle housing cover.
NOTE: Make sure rear axle housing vent and rear axle hose are not plugged.
2. Apply a continuous bead of Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specifications ESE-M4G195-A or ESB-M4G92-A to groove in axle housing cover.
CAUTION: Make sure machined surfaces on both axle housing cover and rear axle housing are clean before installing the new silicone sealant. Inside of axle must be covered when cleaning the machined surface to prevent axle contamination. Tighten the cover bolts in a crosswise pattern to prevent distortion of axle housing cover.
NOTE: Axle housing cover assembly must be installed within 15 minutes of application of the silicone or new sealant must be applied.
3. Position axle housing cover and install retaining bolts (place service identification tag in the 12 o'clock position). Tighten to 27-37 Nm (20-27 ft. lbs.).
4. Install Differential Axle Housing. Service and Repair