Steps 26 - 50

26. Note: A slight drag should be felt for the correct shim selection.

Note: Use a shim to determine shim thickness.

Select and check the correct shim size.
27. Remove the special tool.

28. Note: The same pinion bearings and drive pinion bearing adjustment shim used in the drive pinion shim selection procedure must be used in the final axle assembly.





Install the inner pinion bearing.
1 Position the drive pinion bearing adjustment shim on the pinion stem.
2 Position the pinion bearing on the pinion stem.
3 Position the special tool on the pinion stem.
4 Using a press, firmly seat the drive pinion bearing adjustment shim and pinion bearing on the pinion stem.

29. Note: Make sure the splines on the pinion stem are free of burrs. If burrs are evident, remove using a fine crocus cloth, work in a rotational motion.





Place a new drive pinion collapsible spacer on the pinion stem against the pinion stem shoulder.





30. Install the drive pinion and drive pinion collapsible spacer into the rear axle housing.
31. Install the outer pinion bearing, the rear axle drive pinion shaft oil slinger and the rear axle drive pinion seal.
32. Note: Lubricate the rear axle pinion flange splines. Use SAE 75W140 Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.





Install the rear axle pinion flange.

- Note: Disregard the scribe marks if a new rear axle pinion flange is being installed.

Align the rear axle pinion flange with the drive pinion shaft.





33. With the drive pinion in place in the rear axle housing, install the rear axle pinion flange using the special tools.

34. CAUTION: Do not under any circumstance loosen the pinion nut to reduce preload. If it is necessary to reduce preload, install a new collapsible spacer and pinion nut.








Use the special tool to hold the pinion flange while tightening the pinion nut.
- Rotate the pinion occasionally to make sure the differential pinion bearings seat correctly. Take frequent differential pinion bearing torque preload readings by rotating the pinion with a Nm (inch/pound) torque wrench.





35. Draw-file the differential ring gear mounting surface to remove any nicks or burrs.





36. Install the ring gear.
1 Place the ring gear onto the differential case.
2 Hand start three bolts to align the holes in the ring gear and the differential case.
3 Place the differential case and ring gear onto the press bed blocks with the ring gear teeth facing down.
4 Press the ring gear into place.





37. Install the remaining ring gear bolts and tighten to specification.

38. Note: Apply a light coating of Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B to the differential bearing shim to help hold in place.

Note: Select the correct size differential bearing shims by using the differential bearing shim selection chart.





Install the differential bearing shims.
- Place the differential bearing shims in the rear axle housing.





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





40. Install the bearing caps in their original positions and tighten the bolts to specification.





41. Move the Dial Indicator to the 12 o'clock position.

Measuring for backlash





42. Note: Measure the ring gear backlash at four places to obtain a consistent reading.

Note: Turn the ring gear without turning the pinion gear.

Measure the backlash.
- If the backlash is within specification, refer to Backlash within specification.
- If a zero backlash condition occurs, refer to Zero backlash.
- If the backlash is not within specification, refer to Backlash not within specification.





Zero backlash

43. If a zero backlash condition occurs, add 0.51 mm (0.02 inch) to the RH side and subtract 0.51 mm (0.02 inch) from the LH side to allow backlash indication.
- Check the backlash. Repeat Measuring ring gear backlash.
Backlash not within specification





44. To increase or decrease the backlash, remove the bearing caps and install a thicker shim or a thinner shim as shown.
- If the backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness of the other differential bearing shim by the same amount.
45. Rotate the differential several times to make sure the differential bearings are correctly seated.
- Do not turn the pinion flange in order to rotate the differential.





46. Use the special tool to recheck the backlash
- If the backlash is within specification, refer to Backlash within specification. If the backlash is not within specification, repeat Measuring ring gear backlash.





47. Remove the bearing caps and bolts.
- To establish differential bearing preload, use the special tool to increase both left and right shim sizes by the specification shown.
- Use the special tool to ensure that the differential bearing shims are fully seated and the assembly turns freely.





48. Install the bearing caps and bolts and tighten them to specification.





49. Use the special tool to recheck the backlash.





50. CAUTION: Make sure the machined surfaces on both the rear axle housing and the differential housing cover are clean and free of oil before installing the new silicone sealant. The inside of the rear axle must be covered when cleaning the machined surface to prevent contamination.

Install the differential housing cover.
- Apply a new continuous bead of sealant to the differential housing cover. Use Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specifications ESB-M4G92-A.
51. Install the rear axle.
52. Refill the rear axle.
- Fill the rear axle 3 - 5 mm (1/8 - 3/16 inch) from the bottom of the filler hole with SAE 75W140 Synthetic Rear Axle Lubricant FlTZ-19580-B or equivalent meeting Ford specification SL-M2C192-A.