Assembly
DRIVE PINION SHIM SELECTIONPerform Drive Pinion Shim Selection procedure before begining assembly. Adjustments
PINION BEARING & CUP INSTALLATION
1. Install new differential drive pinion bearing cups with Pinion Bearing Cup Replacer T71P-4616-A. Make sure differential drive pinion bearing cups are properly seated in their bores. If a 0.038 mm (0.0015 inch) feeler gauge can be inserted between differential drive pinion bearing cup, differential drive pinion bearing cup is not properly seated.
NOTE: When replacing differential drive pinion bearing cups also replace differential pinion bearings.
DRIVE PINION SEAL INSTALLATION
NOTE: The same differential pinion bearing used in this procedure must be used in final assembly of the rear axle assembly:
1. Place the drive pinion bearing adjustment shim on the pinion and press the differential pinion bearing assembly until it is firmly seated on the shaft with Pinion Bearing Cone Replacer T53T-4621-C.
2. Make sure splines on pinion stem are free of burrs. If burrs are evident, remove using fine crocus cloth, working in a rotational motion. Wipe pinion clean.
2. Place new differential drive pinion collapsible spacer on pinion stem against the pinion stem shoulder.
3. Install differential pinion bearing and rear axle drive pinion shaft oil slinger in housing bore and install rear axle drive pinion seal on Pinion Seal Replacer T79P-4676-A.
CAUTION: Installation without 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 rear axle drive pinion seal surface before installing seal in housing bore. Coat lips of seal with Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B.
4. Install rear axle drive pinion seal in rear axle housing.
5. From rear of rear axle housing, install drive pinion assembly (drive pinion, drive pinion bearing adjustment shim), differential pinion bearing cone and roller and differential drive pinion collapsible spacer) into the rear axle housing.
UNIVERSAL JOINT FLANGE INSTALLATION
1. Apply small amount of SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or -KL or equivalent meeting Ford specification WSP-M2C 197-A to rear axle universal joint flange splines.
2. Align mark on rear axle universal joint flange with mark on pinion shaft.
NOTE: If installing new rear axle universal joint flange, disregard mark on 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 rear axle universal joint flange must never be hammered on or installed with power tools.
4. Install new pinion nut on pinion shaft (apply small amount of SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or -KL or equivalent meeting Ford specification WSP-M2C 197-A on washer side of nut).
5. Hold rear axle universal joint flange with Companion Flange Holding Tool T78P-4851-A while tightening nut.
6. Tighten pinion nut. Rotate pinion occasionally to make sure differential pinion bearing seats properly. Take frequent differential pinion bearing torque preload readings until original recorded preload reading is obtained.
NOTE: Never back off pinion nut to reduce preload. If reduced preload is required, install new differential drive pinion collapsible spacer and pinion nut.
7. If the original recorded preload is less than specification, tighten used differential pinion bearings to 0.9-1.6 Nm (8-14 in. lbs.) and new differential pinion bearings to 1.8-3.2 Nm (16-28 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.
2. Apply continuous bead of Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specifications ESB-M4G92-A or ESE-M4G 195-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 new silicone rubber. Inside of axle must be covered when cleaning machined surface to prevent axle contamination.
NOTE: Axle housing cover assembly must be installed within 15 minutes of application of silicone rubber or new silicone rubber 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.).
CAUTION: Tighten axle housing cover bolts in a crosswise pattern to prevent distortion of axle housing cover.
NOTE: Make sure rear axle housing vent and rear axle hose are clear from restrictions.
4. Install Differential Axle Housing. Service and Repair