Remove the spreader from the carrier.
Section 05-02D: Axle, Rear, Dana | 1996 F-Super Duty Workshop Manual |
Ring Gear and Pinion Backlash
Before installing differential to housing, refer to Ring Gear and Pinion Backlash Adjustments in this section.
NOTE: Care should be taken to avoid nicking the teeth of the ring gear and speed sensor ring during assembly.
Assemble differential drive pinion bearing cups (4616) to differential bearings (4221). Install differential (4026) into carrier.
Use a rawhide hammer to seat differential into crossbore of carrier.
Remove the spreader from the carrier.
NOTE: Mating letters are stamped on rear axle bearing retaining caps and carrier. Matching letters is important at time of assembly. Letters are in vertical and horizontal positions.
Install differential bearing retaining caps. Align the letters stamped on the differential bearing retaining caps with those on the carriers. Tighten screws of rear axle bearing retaining caps to 95-122 Nm (70-90 lb-ft).
Check ring gear and pinion backlash at three equally spaced points with dial indicator.
Backlash tolerance is 0.13-0.203mm (0.005-0.008 inch) and cannot vary more than 0.05mm (0.002 inch) between points checked.
High backlash is corrected by moving the ring gear closer to the pinion.
Low backlash is corrected by moving ring gear away from the pinion.
These corrections are made by switching differential bearing shims (4067) from one side of the differential case (4204) to the other.
To confirm total preload, recheck torque to rotate with an pound-inch wrench as shown. The reading should be higher than the initial reading (taken without the differential case installed as described under Pinion Position Shim Selection by the following amount if new bearings have been installed as recommended:
4.63 and 5.13 ratios = 6-8 lb-in
If total preload is too high, remove an equal amount of differential bearing shims from each differential case hub. If total preload is too low, add an equal amount of differential bearing shims to each differential case hub.
To verify the final pinion position, refer to Adjustments, Ring Gear and Pinion Tooth Pattern Interpretation in this section.
CAUTION: Clean both flat surfaces with a suitable solvent to remove all traces of oil film.
Install new axle housing cover gasket and install axle housing cover (4033). Tighten screws to 41-54 Nm (30-40 lb-ft) as detailed below.
The following figure shows the flat mounting surface axle housing cover on Dana design rear axles (4001). This axle housing cover requires the use of a silicone rubber sealer material such as Silicone Rubber E7TZ-19562-A or equivalent meeting Ford specification ESL-M4G273-A rather than a gasket.
The axle housing cover face of the carrier and the flat surface of the axle housing cover must be free of any oil film or foreign material.
Sealant material must meet specifications of ESL-M4G273-A, ASTM1, GE503, Z1, Z2 and Z3 sealant or equivalent.
NOTE: Axle housing cover must be installed within 15 minutes of application of the silicone or new sealant must be applied.
Apply Silicone Rubber E7TZ-19562-A or equivalent meeting Ford specification ESL-M46273-A to surface of axle housing cover. Lay sealer bead 3.18-6.35mm (1/8 to 1/4 inch) wide on the inside of the axle housing cover screw holes. The bead is not to pass through the holes or outside of the holes.
Assemble two axle housing cover screws into axle housing cover at 8 o'clock and 2 o'clock position. Use these two holes to guide axle housing cover into position on the carrier.
Install remaining screws. Tighten alternately and evenly. Tighten screws to 41-54 Nm (30-40 lb-ft). Allow one hour cure time before filling carrier with the proper amount of specified lubricant. Refer to the Specifications portion of this section.
Install axle shaft (4234). Refer to Section 05-02E.
Fill rear axle housing (4010) with specified amount of rear axle lubricant meeting Ford specification WSP-M2C197-A. Refer to Specifications, Axle Specifications in this section.