Axle Assembly

Pinion Bearing Cup Installation

NOTE: To ensure proper seating, clean bores before installing rear axle pinion bearing cups (4628) .

Install the new rear axle pinion bearing cups with Pinion Bearing Cup Replacer T71P-4616-A. Make sure the rear axle pinion bearing cups are properly seated in their bores. If a 0.038mm (0.0015 inch) feeler gauge can be inserted between a rear axle pinion bearing cup and the bottom of its bore at any point around the rear axle pinion bearing cup , the rear axle pinion bearing cup is not properly seated. Whenever the rear axle pinion bearing cups are replaced, the differential pinion bearings (4630) should also be replaced.

Drive Pinion Shim Selection

A drive pinion bearing adjustment shim (4663) (0.254-0.965mm (0.010-0.038 inch)) is used between the differential pinion bearing and the pinion head. The drive pinion bearing adjustment shim compensates for machining variations in the rear axle housing (4010) , differential ring gear and pinion (4209) and differential pinion bearings (4621) . The correct drive pinion bearing adjustment shim size will locate the pinion for proper tooth contact with the ring gear. Selecting the correct drive pinion bearing adjustment shim when installing a new differential ring gear and pinion can be done by using Pinion Depth Gauge T79P-4020-A as follows:

1. Assemble the appropriate aligning adapter, gauge disc and gauge block to the screw as shown.

NOTE: The gauge block must be off-set to obtain an accurate reading.

2. Place the rear differential pinion bearing (new, or used if in good condition) over the aligning disc and insert into the rear axle pinion bearing cup of the carrier. Place the differential pinion bearing into the bearing cap and assemble the tool handle into the screw and tighten to 2.2 Nm (20 lb-in).
   
   
   
   

3. Make sure that the gauge handle adapter screw, aligning adapter, gauge disc and gauge block assembly are securely mounted between the differential pinion bearing and differential pinion bearing . Check the tool handle torque prior to gauging to ensure that bearings are properly seated, resulting in accurate shim selection. Clean rear axle pinion bearing cups and differential bearing bore surfaces thoroughly. Apply only a light oil film on bearing assemblies prior to gauging.

4. The gauge block should then be rotated several half turns to ensure rollers are properly seated in rear axle pinion bearing cups . Rotational torque on the gauge assembly should be 2.2 Nm (20 lb-in) with new bearings. Final position should be approximately 45 degrees across gauge tube to ensure that gauge block is in line with gauge tube high point. This area should be utilized for drive pinion bearing adjustment shim selection. Selection of drive pinion bearing adjustment shim with gauge block not lined up with tube high point will cause improper drive pinion bearing adjustment shim selection and may result in axle noise.

   NOTE: Shims must be flat. Do not use dirty, bent, nicked or mutilated shims as a gauge.

5. Use drive pinion bearing adjustment shims as the gauge for shim selection. This will minimize errors in attempting to stack feeler gauge stock together or simple addition errors in calculating correct shim thickness.

   NOTE: A tooth pattern check with the marking compound and road testing is not required when Pinion Depth Gauge T79P-4020-A or equivalent is used.

6. It is important to feel a slight drag on the differential bearing shim (4067) for correct selection. Do not attempt to force the differential bearing shim between the gauge block and the gauge tube. This will minimize selection of a differential bearing shim thicker than required which results in a deep tooth contact in final assembly of integral axles.

Drive Pinion and Flange Yoke Seal Installation

1. Install differential pinion bearing and drive pinion bearing adjustment shim , using Pinion Bearing Cone Replacer T53L-4621-C.
   
   
   
   

2. Install rear differential pinion bearing .
   
   
   
   

3. Place differential drive pinion bearing spacer (4662) on pinion stem against pinion stem shoulder.
   
   
   
   

    CAUTION: Installation without proper tool may result in early flange yoke seal failure. If flange yoke seal (4676) becomes cocked during installation, remove and replace with new flange yoke seal .

4. Clean the flange yoke seal seat surface and install flange yoke seal on Pinion Seal Replacer T79P-4676-A and install flange yoke seal in rear axle housing . If not pre-greased, apply Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B between the lips of the flange yoke seal .
   
   
   
   

5. Install the differential pinion bearing and drive pinion oil seal deflector (4859) in the housing bore and install the flange yoke seal on the Pinion Seal Replacer T79P-4676-A.

6. Check splines on the pinion shaft to be sure they are free of burrs. If burrs are evident, remove them by using a fine crocus cloth. Working in a rotating motion, wipe the pinion clean.

7. Position pinion in rear axle housing .

Universal Joint Flange, Rear Axle Installation

 CAUTION: The rear axle universal joint flange (4851) must never be hammered on, or assembled with power tools.

1. Apply a small amount of axle lubricant to rear axle universal joint flange splines.

2. Align mark on the rear axle universal joint flange with the mark on the pinion shaft. Install rear axle universal joint flange .

3. Install a new nut on pinion shaft. Apply a small amount of axle lubricant on the washer side of nut.

4. Hold the rear axle universal joint flange with Companion Flange Holding Tool T78P-4851-A while tightening the nut.
   
   
   
   

5. Rotate pinion occasionally to ensure proper bearing seating. Take frequent pinion bearing torque preload readings while tightening until the original recorded preload reading is obtained.

    CAUTION: The circular companion flange must never be hammered on, or assembled with power tools.

6. If the original recorded preload is less than specification, tighten to specification. If the preload is higher than specification, tighten to original reading as recorded.

   Under no circumstances should the pinion nut be backed-off to reduce preload. If reduced preload is required, a new differential drive pinion bearing spacer and pinion nut should be installed.

Differential Case Installation

Condition 1

Follow this procedure only when differential ring gear and pinion replacement is required and the differential bearings (4221) and the differential case (4204) do not require replacement.

1. Remove differential caps and bolts. Identify RH cap, RH differential bearing and differential bearing shim to keep these components as RH and LH sets.

2. Remove differential case using the pry bar method. Reasonable effort will be required to remove subassembly if preload is within specification range. If subassembly can be removed by hand, use Condition 2 for assembly.

3. Replace ring and pinion members utilizing differential bearing shim components from original assembly and select the drive pinion bearing adjustment shim as outlined. ( Differential bearing shims may be reused with the exception of drive pinion bearing adjustment shim which will require regauging and certification before reassembly.)

Condition 2

Follow this procedure when original differential bearing shims are not available or when rear axle housing, differential case or differential bearing replacement is required.

1. With pinion depth set and pinion installed, place the differential case/gear subassembly with differential bearings and differential bearing cups (4222) in rear axle housing .
   
   
   
   

2. Install a 6.74mm (0.265-inch) differential bearing shim on the LH side.
   
   
   
   

3. Install LH bearing cap finger-tight.
   
   
   
   

4. 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.
   
   
   
   

5. Install RH side bearing cap and tighten differential bearing cap bolts to 95-115 Nm (70-85 lb-ft).
   
   
   
   

6. Rotate assembly to ensure free operation.
   
   
   
   

7. Check ring gear and pinion backlash. If backlash is within specification, go to Step 14. If backlash is not within specification, go to Step 10. If zero backlash is measured, proceed with Step 8.
   
   
   
   

8. If a zero backlash condition occurs, add 0.50mm (0.020 inch) to the RH side and subtract 0.50mm (0.020 inch) from the LH side to allow backlash indication.
   
   
   
   

9. Check backlash as outlined in Step 7.

10. If backlash is not to specification, correct backlash by increasing thickness of one differential bearing shim and decreasing thickness on the other differential bearing shim by the same amount. Refer to the following illustration for approximate differential bearing shim change.
    
    
    
    
    
    

    Backlash Change Required		Thickness Change Required
    inch	mm	inch	mm
    0.001	0.025	0.002	0.050
    0.002	0.050	0.002	0.050
    0.003	0.076	0.004	0.101
    0.004	0.101	0.004	0.152
    0.005	0.127	0.006	0.152
    0.006	0.152	0.008	0.203
    0.007	0.177	0.010	0.254
    0.008	0.203	0.010	0.254
    0.009	0.228	0.012	0.304
    0.010	0.254	0.014	0.355
    0.011	0.279	0.014	0.355
    0.012	0.304	0.016	0.406
    0.013	0.330	0.018	0.457
    0.014	0.335	0.018	0.457
    0.015	0.381	0.020	0.508

    
    

    Refer to the following chart for specific differential bearing shim thicknesses.
    
    
    
    
    
    

    DIFFERENTIAL SHIM SIZE CHART

    Number of Stripes and Color Code	Dimension A
    	inch	mm
    2—C-COAL	0.3070—0.3075	7.7978—7.8105
    1—C-COAL	0.3050—0.3055	7.747—7.7597
    5—BLU	0.3030—0.3035	7.6962—7.7089
    4—BLU	0.3010—0.3015	7.6454—7.6581
    3—BLU	0.2990—0.2995	7.5946—7.6072
    2—BLU	0.2970—0.2975	7.5438—7.5565
    5—PINK	0.2930—0.2935	7.4422—7.4549
    4—PINK	0.2910—0.2915	7.3914—7.4041
    3—PINK	0.2990—0.2995	7.3406—7.3533
    2—PINK	0.2970—0.2975	7.2898—7.3025
    1—PINK	0.2950—0.2955	7.239—7.2517
    5—GRN	0.2830—0.2835	7.1882—7.2009
    4—GRN	0.2810—0.2815	7.1374—7.1501
    3—GRN	0.2790—0.2795	7.0866—7.0993
    2—GRN	0.2770—0.2775	7.0378—7.0485
    1—GRN	0.2750—0.2755	6.985—7.0485
    5—WH	0.2730—0.2735	6.9342—6.9469
    4—WH	0.2710—0.2715	6.8843—6.8961
    3—WH	0.2690—0.2695	6.8326—6.8453
    2—WH	0.2670—0.2675	6.7818—6.7945
    1—WH	0.2650—0.2655	6.731—6.7437
    5—YEL	0.2630—0.2635	6.6802—6.6929
    4—YEL	0.2610—0.2615	6.6294—6.6421
    3—YEL	0.2590—0.2595	6.5786—6.5913
    2—YEL	0.2570—0.2575	6.5278—6.5405
    1—YEL	0.2550—0.2555	6.4770—6.4897
    5—ORNG	0.2530—0.2535	6.4262—6.4389
    4—ORNG	0.2510—0.2515	6.3754—6.3881
    3—ORNG	0.2490—0.2495	6.3246—6.3373
    2—ORNG	0.2470—0.2475	6.2738—6.2865
    1—ORNG	0.2450—0.2455	6.223—6.2357
    2—RED	0.2430—0.2435	6.1722—6.1849
    1—RED	0.2410—0.2415	6.1214—6.1341

    
    

11. Install differential bearing shim and bearing caps. Tighten caps to 95-115 Nm (70-85 lb-ft).
    
    
    
    

12. Rotate assembly several times.
    
    
    
    

13. Check backlash as outlined in Step 7. If backlash is within specification, proceed to Step 14. If not, repeat Step 10.

14. Increase both LH and RH shim sizes by 0.1524mm (0.006-inch) and install for correct differential bearing preload. Make sure the differential bearing shims are fully seated and the assembly turns freely.
    
    
    
    

15. Use a white marking compound to obtain a tooth mesh contact pattern in the assembly. Pattern legibility can be improved by connecting the driveshaft and rotating both wheels (1007) in the drive and coast direction.

Axle Shaft Installation

 CAUTION: Care must be taken not to let axle shaft splines damage inner wheel bearing oil seal (1177) or rear wheel bearing (1225) assembly.

1. Carefully slide the axle shaft (4234) into the rear axle housing , without damaging rear wheel bearing or inner wheel bearing oil seal assembly. Start the splines into the differential side gear (4236) and push firmly until the button end of the axle shaft can be seen in the differential case .

2. Install the rear axle shaft retaining u-washer (4N237) on the button end of the axle shaft splines, then push the axle shaft outboard until the shaft splines engage and the rear axle shaft retaining u-washer seats in the counterbore of the differential side gear .

    CAUTION: Differential pinion shaft lock pin (4241) must be tightened to specification using Stud and Bearing Mount E0AZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1.

3. Position the differential pinion shaft (4211) through the differential case and differential pinion gears (4215) aligning hole in shaft with differential pinion shaft lock pin hole. Install differential pinion shaft lock pin Tighten to 20-41 Nm (15-30 lb-ft).
   
   
   
   

Cover Installation

 CAUTION: Make sure machined surfaces on both axle housing cover (4033) and rear axle housing are clean before installing new silicone sealant. Inside of axle must be covered when cleaning machined surface to prevent axle contamination. Tighten cover axle housing cover bolt (4346) in a crosswise pattern to ensure uniform draw on axle housing cover .

1. Apply a continuous bead of Silicone Rubber D6AZ-19562-AA or BA(ESB-M4G92A or ESB-M4G195-A) or equivalent to the axle housing cover .

2. Install axle housing cover . Tighten axle housing cover bolts to 38-52 Nm (28-38 lb-ft).

3. Add Rear Axle Lubricant XY-90-QL or -KL or equivalent meeting Ford specification ESP-M2C154-A until it is 6-14mm (1/4-9/16-inch) below bottom of fill hole. Add 118ml (4 oz) of Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A for Traction-Lok axles. Install fill plug and tighten to 20-41 Nm (15-30 lb-ft).

Sensor, Anti-Lock Brake

Installation

1. Install rear brake anti-lock sensor (2C190) .

2. Tighten to 4.5-6.8 Nm (40-60 lb-in).