Axle Assembly

Pinion Bearing Cup Installation

Install the new rear axle pinion bearing cups (4628) 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) (0.254mm to 0.965mm (0.010 to 0.038 inch)) is used between differential pinion bearing and pinion head. The drive pinion bearing adjustment shim compensates for machining variations in 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 pinion for proper tooth contact with ring gear. Selecting correct drive pinion bearing adjustment shim when installing a new differential ring gear and pinion can be done by using Pinion Depth Gauge Set 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 differential pinion bearing (new, or used if in good condition) over aligning disc and insert into rear axle pinion bearing cup of the carrier. Place differential pinion bearing into the bearing cap and assemble the tool handle into 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. This can affect final shim selection when improperly assembled. Clean rear axle pinion bearing cups and differential pedestal surfaces thoroughly. Apply only 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 used 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 drive pinion bearing adjustment 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: The same differential pinion bearing used in this procedure must be used in final assembly of the axle.

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

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

7. Place the selected drive pinion bearing adjustment shims on pinion shaft and press differential pinion bearing until firmly seated on shaft.

Drive Pinion and Flange Yoke Seal Installation

1. Place the drive pinion bearing adjustment shims on the pinion and press the differential pinion bearing until it is firmly seated on the shaft.

2. Check splines on pinion stem to be sure they are free of burrs. If burrs are evident, remove by using a fine crocus cloth, working in a rotational motion. Wipe pinion clean.

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

   NOTE: Clean the flange yoke seal (4676) surface before installing the rear axle drive pinion shaft oil slinger (4670) in the rear axle housing bore. Coat lips of rear axle drive pinion shaft oil slinger with Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B.

4. Install the differential pinion bearing and rear axle drive pinion shaft oil slinger in the housing bore and install the rear axle drive pinion shaft oil slinger on the Pinion Seal Replacer T79P-4676-A.
   
   
   
   

    CAUTION: Installation without the proper tool may result in early flange yoke seal failure. If flange yoke seal becomes cocked during installation, remove it and install new one.

5. Install flange yoke seal in rear axle housing .
   
   
   
   

6. From rear of rear axle housing , install drive pinion assembly (drive pinion, drive pinion bearing adjustment shims , differential pinion bearing and differential drive pinion bearing spacer ) into the rear axle housing pinion shaft bore.

7. Apply a small amount of rear axle lubricant to rear axle universal joint flange (4851) splines.

   NOTE: If a new rear axle universal joint flange is being installed, disregard the scribe mark on the pinion stem.

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

9. With drive pinion in place in rear axle housing , install rear axle universal joint flange using Companion Flange Replacer TOOL-4858-E or equivalent.

    CAUTION: The rear axle universal joint flange must never be hammered on or installed with power tools.

10. Install a new pinion nut on pinion shaft (apply a small amount of lubricant on the washer side of nut).

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

12. Tighten pinion nut. Rotate pinion occasionally to ensure proper bearing seating. Take frequent pinion bearing torque preload readings until the original recorded preload reading is obtained.

     CAUTION: 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 must be installed.

13. If the original recorded preload is less than specification, tighten to 0.9-1.5 Nm (8-14 lb-in) bearings, 1.8-3.2 Nm (16-29 lb-in) new bearings. If the preload is higher than specification, tighten to original reading as recorded.

Differential Case Installation

Condition 1

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

1. Remove the differential caps and bolts. Identify the RH cap, RH differential bearing cup (4222) and differential bearing shim (4067) to keep these components as RH and LH sets.

2. Remove the differential case subassembly 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 the ring and pinion members utilizing the differential bearing shim components from the original assembly and select the drive pinion bearing adjustment shim as outlined. ( Differential bearing shim may be reused with the exception of drive pinion bearing adjustment shim which will require regauging to specification before assembly.)

   NOTE: Tighten rear axle differential gear case bolts (4216) in a crisscross pattern.

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 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 differential bearing cap bolts. Tighten to 95-115 Nm (70-85 lb-ft).
   
   
   
   

6. Rotate the assembly to ensure free operation.
   
   
   
   

7. Check 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 illustrations for approximate differential bearing shim change.

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

12. Rotate assembly several times.
    
    
    
    

13. Recheck 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. Pattern legibility can be improved by connecting the driveshaft (4602) and rotating both wheels (1007) in the drive and coast direction.
    
    
    
    

Tooth Contact Guidelines

Pattern inspection allows the technician to detect gross errors in set-up prior to complete assembly. Pattern contact should be within the primary area of the ring gear tooth surface avoiding "narrow" or "hard" contact with the outer perimeter of tooth (top to root, toe to heel). Pattern inspection should be on the drive (pull) side. Correct assembly of drive pattern will result in satisfactory coast performance. If gross pattern error is detected, with preferred backlash 0.305 to 0.381mm (0.012 to 0.015 inch), check drive pinion bearing adjustment shim selection.

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.

NOTE: Check for presence of rear axle shaft o-ring (4A332) on the spline end of the axle shaft (4234) and install if not present.

1. Carefully slide axle shaft into rear axle housing , without damaging rear wheel bearing or inner wheel bearing oil seal assembly. Start splines into differential side gear (4236) and push firmly until the button end of 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 the hole in the shaft with the differential pinion shaft lock pin hole. Install differential pinion shaft lock pin and tighten to 20-41 Nm (15-30 lb-ft).
   
   
   
   

Cover Installation

NOTE: Axle housing cover (4033) assembly must be installed within 15 minutes of application of the silicone rubber or new silicone rubber must be applied.

 CAUTION: Ensure machined surfaces on both axle housing cover and rear axle housing are clean before installing the new silicone rubber. Inside of axle must be covered when cleaning the machined surface to prevent axle contamination. Tighten the axle housing cover bolts (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 or equivalent meeting Ford specification ESE-M4G195-A and ESB-M4G72-A. Install axle housing cover and tighten axle housing cover bolts to 38-52 Nm (28-38 lb-ft). Tighten ratio tag cover bolt (two o'clock position) to 24-38 Nm (18-28 lb-ft).
   
   
   
   

2. 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).