Axle Assembly

Special Tools:

Removal
1. Raise the vehicle on a hoist or raise the rear end of the vehicle with a jack. Install safety stands under the frame rails and lower the jack or hoist enough to allow the rear axle to drop into the rebound position for working clearance.

2. If so equipped, remove the rear stabilizer bar and links as an assembly.
3. Remove the differential housing cover and drain the lubricant. Clean the gasket material from the differential housing cover and the differential housing.

4. Note: An inspection can find the cause of the concern and determine the resolution.

Carry out the following before disassembly.

- Remove all the lubricant from the internal parts of the differential assembly. Visually inspect the parts for wear and damage.
- Rotate the differential assembly to check for any roughness, indicating damaged bearings or gears.
- Check the differential ring gear and pinion teeth for signs of scoring, abnormal wear, nicks and chips.
- Use a magnet to search for heavy metal particles indicating component damage.

5. CAUTION: The differential ring gear and pinion must be clean and dry to obtain an accurate reading.

Using the special tools, measure the differential ring gear and pinion backlash at three equally spaced points.
- The backlash tolerance is 0.13 - 0.20 mm (0.005 - 0.008 inch) and cannot vary more than 0.05 mm (0.002 inch) between points checked. A backlash variation of more than 0.05 mm (0.002 inch) indicates gear/case runout.
- Make corrections for high or low backlash during assembly by changing the differential bearing selective shim thickness.

6. Remove the axle shafts.

7. CAUTION: Index-mark the driveshaft components to maintain driveline balance. during assembly.

Disconnect the driveshaft at the axle, and position it aside.

8. CAUTION: Note the positions of the mating letters stamped vertically and horizontally on the bearing caps and the differential housing before removing the bearing caps. Matching the letters is important at the time of assembly.

To ease removal of the differential assembly, loosen the bolts, then pry the differential case, bearing cups and outboard spacers outward until they are loose in the differential housing.

9. Remove the bolts and the bearing caps.

10. CAUTION: Do not spread the differential housing more than specified.

Using the special tools, spread the differential housing to the specification. Remove the Dial Indicator with Magnetic Base.

11. CAUTION: It will be necessary to use large pry bars to remove the differential assembly from the differential housing. Do not damage the differential ring rear when carrying out this step.

CAUTION: Mark or tag the differential bearing cups, indicating from which side they were removed.

Remove the differential assembly with the bearing cups.
- Remove the special tool after removing the differential assembly.
- Inspect the differential bearing cups for deep scores, galling and spalling, Discard them if necessary.

12. CAUTION: Mark or tag the outboard spacers indicating from which side they were removed.

Remove the outboard spacers.
- Inspect the spacers for nicks, bending and grooved conditions. Discard them if necessary.

13. CAUTION: Index-mark the pinion flange to the pinion shaft prior to removal.

Use the special tool to prevent the flange from turning while removing the lock nut and washer.

14. Using the special tool, remove the pinion flange.

15. Note: There are drive pinion bearing preload shims and, on Model 70 axles, preload spacers on the spline-end of the pinion. These shims and spacers can stick to the pinion, the pinion bearing, or they can fall out of the differential housing. Collect and keep the shims and spacers for reassembly.

Using a soft-face hammer, tap the pinion out of the pinion bearing cup and remove it through the rear of the differential housing.

16. Using the special tools, remove and discard the pinion seal.
17. Remove the oil slinger and the pinion bearing.

18. CAUTION: Do not nick the differential housing bore.

Using the special tools, remove the outer pinion bearing cup.
- For Model 60/70 axles, use tools 205-DO54 and 205-DO55.
- For Model 80 axles, use tools 205-283 and 205-DO55.

19. Note: On Model 80 axles, discard the drive pinion position shim(s) if bent or nicked. If discarding the shim(s), measure and record the shim(s) thickness.

Using the special tools, remove the inner pinion bearing cup and, on Model 80 axles, the drive pinion position shim(s).
- For Model 60 axles, use tools 205-DO51 and 205-DO55.
- For Model 70/80 axles, use tools 205-DO52 and 205-DO55.

20. The oil slinger, if so equipped, is part of the total drive pinion position shim height required to correctly set pinion depth. Keep the oil slinger intact for assembly.

21. Using the special tool, remove the inner pinion bearing.

22. Note: On Model 60/70 axles, discard the drive pinion position shim if bent or nicked. If discarding the shim, measure and record the shim thickness.

Remove the oil slinger, if so equipped, and, on Model 60/70 axles, the drive pinion position shim.
23. Carry out the following after disassembling the axle:
- Thoroughly clean all parts.
- Inspect all parts for damage and wear.
- Clean the inside of the differential case before assembly.

+ Thoroughly clean the differential housing if the gears have scores/chips in them.

Installation
1. Carry out the Differential Case End Play Check in the General Procedures portion of this section.
2. Position the inner and outer pinion bearing cups and the special tools in their respective differential housing bores.

1 After placing the inner and outer pinion bearing cups in their bores, place the special tool (inner) on the inner pinion bearing cup.
2 Place the special tool (outer) on the outer pinion bearing cup.
3 Install the special tool.

3. Tighten the special tool to seat the pinion bearing cups into their bores.

4. CAUTION: Always install new pinion bearings when installing new bearing cups.

Note: If the feeler gauge can fit between a cup and the bottom of its bore at any point around the cup, remove and reseat the cup.

Check that the cups have seated correctly in their bores.

5. CAUTION: If any of the gauge surfaces have nicks in them, remove the high spots with a medium India oilstone to prevent erroneous readings.

Note: Apply only a light oil film on the pinion bearings before assembling the tools.

Assemble and position the following in the differential housing.

1 Position the Screw.
2 Position the Aligning Adapter.
3 Position the inner pinion bearing.
4 Position the Gauge Disc.
5 Position the Gauge Block.
6 Position the outer pinion bearing.
7 Thread on the Handle.

6. Note: This step simulates pinion bearing preload.

Using a Nm (inch-pound) torque wrench, tighten the Handle to the specification.

7. Note: Offset the Gauge Block to obtain an accurate reading.

Rotate the Gauge Block several half-turns to ensure correct seating of the pinion bearings and position the Gauge Block.
8. Install the special tool.

1 Position the special tool.
+ For Model 60/70 axles, use tool 205-D033.
+ For Model 70HD/80 axles, use tool 205-D038.

2 Install the bearing caps.
3 Install the bolts.

9. Note: Use a feeler gauge or flat, clean drive pinion position shims as a measuring devise.

Note: Do not attempt to force the gauge or shim between the Gauge Block and the Gauge Tube. A slight drag indicates a correct selection.

Using a feeler gauge or flat, clean drive pinion position shims, measure between the Gauge Block and the Gauge Tube. Record the measurement. Refer to Pinion Ring Gear Variation Number for shim selection information.
- Remove the special tools after making the correct shim selection.

10. CAUTION: Follow the drive pinion bearing preload shim and drive pinion position shim assembly sequence as directed or unit failure can result.

On Model 60/70 axles, install the correct thickness drive pinion position shim on the pinion.
11. If so equipped, install the oil slinger on the pinion.

12. Note: Always use the same new inner pinion bearing installed when taking the measurement for drive pinion shim selection.

Using the special tool, an axle bearing/seal plate, and a suitable press, install the pinion bearing.
- For Model 60 axles, use tool 205-092.
- For Model 70 axles, use tool 205-005.
- For Model 80 axles, use tool 205-488.

13. On Model 80 axles, using the special tools, remove the inner pinion bearing cup.
- Use tools 205-DO52 and 205-D055.

14. On Model 80 axles, install the correct thickness of drive pinion position shims in the inner pinion bearing cup bore.

15. On Model 80 axles, position the inner pinion bearing cup and the special tool in the differential housing. Tighten the special tool to seat the inner pinion bearing cup in its bore.

16. Note: If the feeler gauge can fit between a cup and the bottom of its bore at any point around the cup, remove and reseat the cup.

On Model 80 axles, check that the cup seated correctly in its bore.

17. Note: Use the thickness of the old drive pinion bearing preload shims as a starting point for setting pinion bearing preload.

Inspect the drive pinion bearing preload shims for damage. Discard them if necessary. New shims are available in the thickness shown in the following chart.

Available Drive Pinion Bearing Preload Shims (Model 60/70)

Available Drive Pinion Bearing Preload Shims (Model 80)

18. On Model 70 axles, assemble the pinion preload spacers onto the pinion.
19. Assemble the drive pinion bearing preload shims onto the pinion, and install the pinion into the differential housing.
20. Install the outer pinion bearing.

21. Install the pinion flange.
- For Model 80 axles, use the special tool.

22. Use the special tool to prevent the flange from turning while installing the old washer and the lock nut.
- For Model 60/70 axles, tighten the nut to 339 Nm (250 ft. lbs.).
- For Model 80 axles, tighten the nut to 637 Nm (470 ft. lbs.).

23. Using an inch-pound torque wrench, rotate the pinion. The torque must read as specified.
- To increase the preload, remove drive pinion bearing preload shims. To decrease the preload, add shims.

24. If the pinion bearing preload is within specification, and the pinion position shim has changed, change the drive pinion bearing preload shims by the same amount.
- The direction arrow pointing toward the pinion flange indicates that by removing the drive pinion position shim, the distance from the centerline of the tubes to the pinion backface increases, giving a plus (+) reading. The drive pinion bearing preload shim pack does not affect the pinion depth setting. However, if the pinion position is changed, the pinion preload will change and may require adjustment to bring the torque-to-rotate within specification. Arrows on the ring gear illustrate the method to increase or decrease backlash and differential bearing preload.

25. With the drive pinion at the correct preload as determined earlier in this procedure, remove and discard the lock nut and the washer. Use the special tool to prevent the flange from turning.

26. Using the special tool, remove the pinion flange.
27. Lubricate the pinion seal rubber lips.
- Use SAE 8OW-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A

28. Using the special tool, install the pinion seal.
- For Model 60/70 axles, use tool 205-208.
- For Model 80 axles, use tool 205-284.
- After installation, verify that the garter spring did not pop out of the seal. If the garter spring popped out, install a new pinion seal.

29. Coat the inside of the pinion flange with a small amount of lubricant.
- Use SAE 8OW-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A

30. Install the pinion flange.
- For Model 80 axles, use the special tool.

31. CAUTION: Always install a new washer and lock nut.

Use the special tool to prevent the flange from turning while installing the new washer and lock nut.
- For Model 60/70 axles, tighten the nut to 339 Nm (250 ft. lbs.).
- For Model 80 axles, tighten the nut to 637 Nm (470 ft. lbs.).

32. Carry out the Ring Gear and Pinion Backlash procedure in the General Procedures portion of this section.
33. Assemble the differential bearing cups to the differential bearings.

34. CAUTION: Do not spread the differential housing more than specified.

CAUTION: Avoid nicking the ring gear teeth and the anti-lock speed sensor ring during assembly.

Using the special tools, spread the differential housing to the specification.
- Use a rawhide hammer to seat the differential into the differential housing pocket.
1 Remove the special tools.

35. CAUTION: Match the mating letters as noted during disassembly.

Install the bearing caps, aligning the letters with those on the differential housing. Tighten the bolts to specification.

36. Using the special tools, measure the differential ring gear and pinion backlash at three equally spaced points.
- The backlash tolerance is 0.13 - 0.203 mm (0.005 - 0.008 inch) and cannot vary more than 0.05 mm (0.002 inch) between points checked. A backlash variation of more than 0.05 mm (0.002 inch) indicates gear/case runout.
- Move the differential ring gear toward the pinion to correct high backlash.
- Move the differential ring gear away from the pinion to correct low backlash.
- Moving a specified amount of differential bearing shims from one side of the differential to the other makes these corrections.

37. Confirm the total preload.
- Using an inch-pound torque wrench, check the torque to rotate the pinion. The reading must be higher than the initial reading (taken without the differential case installed) by the amount shown, with new bearings installed as recommended.
- If the total preload is too high, remove an equal amount of differential bearing shims from each differential case hub. If the total preload is too low, add an equal amount of differential bearing shims to each differential case hub.

38. Carry out the Tooth Contact Pattern Check to verify the final pinion position is correct.
39. Install the axle shafts.

40. CAUTION: Clean both flat surfaces (differential housing and differential housing cover) with a suitable solvent to remove all traces of oil film.

CAUTION: Install the differential housing cover within 15 minutes of applying the silicone, or it will be necessary to apply new sealant.

Note: The differential housing cover requires a silicone rubber sealer material, such as Ultra Silicone Sealant F7TZ-19554-AA or equivalent meeting Ford specification Dana 5-17, rather than a gasket.

Apply a continuous bead of sealant, of the specified thickness, to the differential housing cover.
- Use Ultra Silicone Sealant F7TZ-19554-AA or equivalent meeting Ford specification Dana 5-17.

41. Place two bolts into the differential housing cover at the 8 o'clock and 2 o'clock positions. Install the differential housing cover.
- Use the two bolts to position the differential housing cover on the differential housing.

42. Install the remaining bolts. Tighten the bolts alternately and evenly.
- Tighten Grade 5 bolts to 47 Nm (35 ft. lbs.).
- Tighten Grade 8 bolts to 61 Nm (45 ft. lbs.).
- Allow 1-hour cure time before filling the axle with the correct amount of specified lubricant.

43. If so equipped, install the rear stabilizer bar and links.

44. CAUTION: Align the index marks made during removal.

Connect the driveshaft to the axle.

45. Fill the axle with the specified type and amount of lubricant.