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ASSEMBLY





1. If the baffle was removed, position the baffle on a Differential Bearing Cone Replacer.

CAUTION: Do not omit the baffle because bearing failure may result.





2. Use the Differential Bearing Cone Replacer to install the baffle.





3. Oil the new pinion bearing cups with Motorcraft SAE75W90 4x4 Axle Lubricant XY-75W90-QL meeting Ford specification WSP-M2C201-A or equivalent and install.
^ Use the Pinion Bearing Cup Replacer to install the bearing cups.

NOTE: Whenever the front pinion bearing cups are replaced, the differential pinion bearing must be replaced.





4. Assemble and position the Pinion Depth Gauge Set.
1 Position the Screw.
2 Position the Aligning Adapter.
3 Position the Gauge Disc.
4 Position the Gauge Block.
5 Position the differential pinion bearing.
6 Position the differential pinion bearing.
7 Thread on the Driver Handle.

NOTE: Apply only a light oil film on the pinion bearings before performing this measurement.





5. Tighten the Driver Handle.





6. Rotate the Gauge Block several half turns to ensure proper seating of the pinion bearings, and position the Gauge Block.

NOTE: The Gauge Block must be offset to obtain an accurate reading.





7. Install the Gauge Tube.
1 Position the Gauge Tube and paper shipping tags.
2 Install the differential bearing caps.
3 Install the bolts.





8. Use a drive pinion bearing adjustment shim as a gauge for shim selection.
^ The pinion bearing adjustment shim is checked between the Gauge Block and the Gauge Tube.

NOTE: Drive pinion bearing adjustment shims must be flat and clean. A slight drag should be felt for correct shim selection. Do not attempt to force the pinion shim between the Gauge Block and the Gauge Tube. This will minimize selection of a pinion shim thicker than required, which results in a deep tooth contact in final assembly of integrated rear axle assemblies.





9. Install the pinion bearing.
^ Place the drive pinion bearing adjustment shim on the pinion.
^ Using a press and the Pinion Bearing Cone Replacer, press the differential pinion bearing until it is firmly seated on the pinion.

NOTE: The same pinion bearing used in this procedure must be used in final axle assembly.





10. Replace the differential drive pinion collapsible spacer on the pinion stem.





11. Install the differential pinion bearing and differential pinion seal.
1 Position the differential pinion bearing.
2 Position the front axle drive pinion shaft oil slinger.
3 Position the differential pinion seal.
4 Use Pinion Seal Replacer to install the differential pinion seal.





12. Position the pinion gear.
1 Apply a small amount of Motorcraft SAE75W90 4x4 Axle Lubricant XY-75W90-QL or equivalent meeting Ford specification WSP-M2C201-A to the pinion gear splines.
2 Position the pinion gear.





13. Align the index marks and position the universal joint flange onto the pinion shaft.

CAUTION: The universal joint flange must never be hammered on or installed with power tools.





14. Using the Companion Flange Replacer, install the front axle universal joint flange.

NOTE: Rotate the pinion occasionally to ensure proper differential pinion bearing seating.





15. Apply a small amount of lubricant to the washer side of the new pinion nut, and install the nut.





16. Tighten the pinion nut.
^ Position the Companion Flange Holding Tool and install the two companion flange holding tool bolts.
^ Tighten the pinion nut.

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. Take frequent differential pinion bearing torque preload readings until the specified preload reading is obtained.

CAUTION: Use extreme care not to damage the aluminum front axle housing while performing these procedures.





17. Install the Master Bearing (LH) and Master Bearing (RH) on the differential case.

CAUTION: Master bearings are marked LH and RH and must be installed as shown.





18. Install the differential case with master bearings into the front axle housing.

Pinion Bearing Adjustment Shim Selection Procedure Worksheet:

19. Measure the total end play.
1 Position a Dial Indicator and Bracketry.
2 Position the indicator tip on the machined surface and adjust to measure full travel.
3 Push the differential case left and right (as far as possible).
4 Measure the total end play and record the reading on the Differential Bearing Shim Selection Procedure Worksheet Line A.

NOTE: Repeat this step until a consistent reading is obtained.





20. Remove the differential case.
1 Remove the Dial Indicator Bracketry and Dial Indicator.
2 Remove the differential case.





21. Use a fine flat file to remove any burrs or nicks from the differential ring gear and pinion mounting surface.





22. Install the ring gear.
^ Position and then start three ring gear bolts to align the holes in the ring gear and the differential case.
^ Use an appropriate press to install the ring gear.





23. Install the remaining ring gear bolts.





24. Remove the three ring gear bolts.





25. Position the differential case.
1 Install the Master Bearing (LH) and the Master Bearing (RH) on the differential case.
2 Position the differential case in the front axle housing with the three missing bolts positioned down.





26. Position the Dial Indicator and Bracketry.





27. Push and rock the ring gear into mesh with the pinion gear (zero backlash) and set the Dial Indicator at zero.





28. Move the ring gear away from the pinion gear as far as possible and record the reading on the drive Pinion Bearing Adjustment Shim Selection Procedure Worksheet Line B.





29. Remove the Dial Indicator and Bracketry.





30. Remove the differential case, the Master Bearing (LH) and the Master Bearing (RH).





31. Clamp the Bearing Preload Tool base in a soft jawed vise with the bearing mounting surface above the surface of the vise.

NOTE: Both differential bearing stand heights must be measured prior to installation on the differential case. Mark the left and right differential bearings before measuring.





32. Position the differential bearing assembly in the Bearing Preload Tool and tighten the tool.





33. Measure the differential bearing stand height.
1 Invert the Bearing Preload Tool and bearing assembly in the vise.
2 Use a depth micrometer to measure and record the differential bearing stand height.
^ Repeat the procedure for the other bearing.

34. Select appropriate differential bearings.

Differential Shim Size Chart:

35. Select the appropriate shim by the thickness or the stripe color.