Steps 1 - 25

Special Tools:

Disassembly
1. Check the ring gear runout.

1 Remove the differential housing cover.
2 Install the special tool.
3 Check and note the ring gear runout.

2. Note: The Housing Spreader Adapters are used here to give the rear axle housing stability. Do not spread the rear axle housing.

Mount the rear axle housing on the Holding Fixture.

1 Attach the Housing Spreader Adapters to the rear axle housing with four cover bolts.
2 Attach the Housing Spreader Adapters to the Holding Fixture with two 3/8 inch x 1-1/2 inch bolts.

3. Note: Mark the position of the bearing caps as arrows may not be visible. The bearing caps must be installed in their identical locations and positions.

Remove the differential bearing caps.

4. Remove the differential case.

5. Remove the 10 ring gear bolts.

6. CAUTION: Care should be taken not to damage the bolt hole threads.

Insert a punch in the bolt holes and drive the ring gear off.

7. Using the special tools, remove the differential bearing.
- Repeat for the other side.

8. Remove the differential pinion shaft lock bolt.

9. Remove the differential pinion shaft.

10. Remove the differential gears.

11. Remove the differential side gears.

12. Install a Nm (inch/pound) torque wrench on the pinion nut and record the torque necessary to maintain rotation of the drive pinion gear through several revolutions.

13. CAUTION: After removing the pinion nut, discard it. Use a new nut for installation.

Note: Make sure to insert the cotter key into the special tool as shown.

Remove the pinion nut.
1 Install the special tool.
2 Install a suitable breaker bar and remove the nut.

14. Mark the pinion flange in relation to the drive pinion stem to ensure correct alignment during installation.

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

16. Install the special tool and, with a soft-faced hammer, drive the pinion out of the front bearing cone and remove it through the rear of the housing.
- Remove the rear axle drive pinion shaft oil slinger, the rear axle drive pinion seal and the collapsible spacer.

17. Remove the front pinion bearing.
1 Position the special tool under the pinion bearing.
2 Using a press, remove the pinion bearing.

18. Note: Measure the drive pinion bearing adjustment shim, which is found under the differential pinion bearing, with a micrometer and record the thickness (use this as a reference to compare the shim gauge reading prior to installing the differential pinion bearing).

Remove the drive pinion bearing adjustment shim.

19. Remove damaged rear axle pinion bearing cup from the rear axle housing using the special tools.

20. Remove damaged rear axle pinion bearing cup from the rear axle housing using the special tools.

Assembly
All vehicles

1. CAUTION: Lubricate the differential side gear thrust washers with Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B prior to installation.

Install the differential side gears in the differential case.

2. CAUTION: Lubricate the differential pinion thrust washers with Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B prior to installation.

Install the differential pinion gears with the differential pinion thrust washers in the differential case.

3. Note: If a new pinion shaft lock bolt is unavailable, coat the threads with Thread lock and Sealer EOAZ-19554-AA or equivalent meeting Ford specifications WSK-M2G315-A5 prior to installation.

Install the differential pinion shaft and install a new differential pinion shaft lock bolt.

4. Use the special tool to install the differential bearing on the differential case. Repeat for the other side.

5. Press the ring gear on the differential case.
- Start two of the ring gear bolts through the differential case and into the ring gear to make sure the ring gear bolt holes align with the differential case bolt holes correctly.

6. Install the ring gear bolts.
- Apply Stud and Bearing Mount E0AZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to the ring gear bolts.

7. Note: If the ring gear runout check (carried out before disassembly) exceeds specification, the cause may be a warped ring gear, a damaged differential case or loss of differential bearing preload.

With the pinion removed, place the differential case/gear subassembly with the differential bearing and the rear axle pinion bearing cups in the rear axle housing.

8. Install a differential bearing shim of the thickness shown on the LH side of the differential case.

9. Install the LH bearing cap finger-tight.

10. Note: Apply pressure toward the left side to fully seat the differential bearing cup.

Install progressively larger differential bearing shims on the RH side until the largest differential bearing shim selected can be assembled with a slight drag feel.

11. Install the RH bearing cap.
- Tighten both bearing caps to specification.

12. Rotate the differential assembly to make sure it rotates freely.

13. Install the special tool.
- Check and note the ring gear runout.
14. If the runout is within specification, the original out-of-specification runout was caused by insufficient bearing preload.
- If the runout exceeds specification, carry out the following steps.

Runout exceeds specification

15. Remove the differential case.

16. Remove the ring gear.

17. Install the differential case without the ring gear.
- Rotate the differential case to correctly seat the differential bearings.

18. Check the differential case flange runout using the special tool.
- If the runout is within specification, install a new ring gear and pinion. If the runout exceeds specification, the ring gear is true and the concern is due to either a damaged differential case or differential bearings.
- Inspect the differential bearings. If the differential bearings are not damaged, install a new differential case and the differential bearings.
- Recheck the runout with the new differential case and differential bearings.

Pinion bearing cup installation with special tool 205-153, 205-480, and 205-054

19. Install a new inner rear axle pinion bearing cup in the rear axle housing.

20. Install a new outer rear axle pinion bearing cup in the rear axle housing.

Pinion bearing cup installation with special tool
205-054

21. Note: Coat the new rear axle pinion bearing cup with SAP 5W-30 Super Premium Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2Cl 53-G.

Install the pinion bearing cup.
1 Position the rear axle pinion bearing cup on the special tool.
2 Position the bearing cup replacer in the rear axle housing.
3 Tighten the special tool to fully seat the rear axle pinion bearing cup in the bore.

All vehicles

22. Note: A drive pinion bearing adjustment shim is used between the pinion bearing and the pinion head. The drive pinion bearing adjustment shim compensates for machining variations in the differential pinion and the pinion bearings. The correct drive pinion bearing adjustment shim size will locate the pinion for correct tooth contact with the ring gear. Selecting the correct drive pinion bearing adjustment shim can be done using a pinion depth gauge set.

Note: Apply a light film of SAE 75W140 Synthetic Rear Axle Lubricant FlTZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A on the front differential pinion bearing and the rear differential pinion bearing assemblies.

Install the special tools.

23. Note: This step duplicates pinion bearing preload. Thread the Handle onto the Screw and tighten to the specification shown.

24. Note: The special tool must be offset to obtain an accurate reading.

Note: Rotate the special tool several half turns to correctly seat the pinion bearings.

Position the special tool 45 degrees as shown.

25. Install the special tool.
1 Position the special tool on the differential bearing seat of the rear axle housing.
2 Install the differential bearing caps.
3 Install the differential bearing cap bolts and tighten to specification.