Steps 33 - 75

33. Move the ring gear away from the pinion gear as far as possible. Record the reading on the Differential Bearing Shim Selection Procedure Worksheet, Line B, in this procedure.





34. Remove the special tools.





35. Remove the differential case and the special tools.





36. NOTE: Measure both of the differential bearing stand heights prior to installing them on the differential case.

NOTE: Mark the left and right differential bearings before measuring them.

Clamp the special tool base in a soft jawed vise with the bearing mounting surface above the surface of the vise.





37. Position the differential bearing assembly in the special tool, and tighten the tool.





38. Measure the differential bearing stand height.
1 Invert the special tool and bearing assembly in the vise.
2 Use a depth micrometer to measure and record the differential bearing stand height.
^ Repeat this procedure for the other bearing.

39. Select appropriate differential bearing shims.











Differential Bearing Shim Selection Chart





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








Differential Shim Size Chart





41. Install the three bolts.





42. CAUTION: Press against the bearing inner cone only.

Using a suitable press and the special tool, install the differential bearings.
1 Position the appropriate differential bearing (RH or LH)
2 Using it suitable press and the special tool, install the differential bearing
^ Repeat the procedure for the other differential bearing.





43. NOTE: Make sure the indicator needle is in the spreader adapter hole.

Install the special tools.





44. CAUTION: Overspreading can damage the axle housing.

Spread the axle housing to the specification.
^ Remove the Dial Indicator.





45. CAUTION: Never attempt to drive the differential bearing shim in place. Permanent damage to the machined axle housing surfaces can occur.

If removed, position the differential bearing shims.
1 Apply a light coating of Premium Long Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B to one side of the differential bearing shims to help hold them in place.
2 Position the differential bearing shims.





46. NOTE: Push the differential case downward to fully seat the differential bearing cups in the axle housing.

Position the differential case assembly.
1 Position the differential bearing cups on the differential bearings.
2 Lower the differential case assembly in place between the differential bearing shims.





47. Install the bearing caps in their original positions and tighten with the housing still spread.
1 Position the bearing caps.
2 Install the bolts.
3 Remove the special tool.





48. Install the special tool.





49. Measure the ring gear backlash at four places to obtain a consistent reading.
1 Mount the special tools on the indicator base.
2 Position the indicator needle and zero the indicator.
3 Turn the ring gear without turning the pinion gear and record the measurement.





50. NOTE: If the backlash is not within the specifications, correct it by increasing the thickness of one differential bearing shim and decreasing the thickness on the other differential bearing shim by the same amount.

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





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 shifts 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-M1C171-A.





53. Install the axle shaft shift lever.
1 Position the clutch fork.
2 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-1-C or equivalent meeting Ford specification ESA-M1C75-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 Fold specification WSE-M4G323-A4





60. Assemble the axle housing tube.
^ Alien 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.