Section 05-03B: Axle, Front Drive, Dana Model 60 Monobeam | 1996 F-350 4x4 Workshop Manual |
Assembly
NOTE: An easy way to assemble the differential side gears and pinion gears is to have all parts lubricated before assembly.
Place differential case (4204) in vise. Apply High Temperature 4x4 Front Axle and Wheel Bearing Lubricant E8TZ-19590-A or equivalent meeting Ford specification ESA-M1C198-A, to new differential side gear thrust washers (4228) and to hubs and thrust face of the new differential side gears.
Assemble both differential side gears. Apply grease to differential pinion thrust washers (4230) and new pinion gears. Assemble new differential pinion gears (4215) and differential pinion thrust washers.
Assemble both differential side gears and differential side gear thrust washers, hold in place with hand, then assemble the pinion gears and differential pinion thrust washers to hold the differential side gears in place.
Rotate the differential side gears until the holes of the differential side gear thrust washers and pinion gears line up with the holes of the differential case. If the differential side gears cannot be rotated by hand, install one of the axle shafts into the spline of the differential side gear and use a pipe wrench to turn the shaft.
Use a drift to line up the holes with those of the differential case.
Assemble differential pinion shaft (4211), drive on differential pinion shaft to remove drift. Align hole of the roll pin of the differential pinion shaft with the hole of the differential pinion shaft lock pin (4241) of the differential case.
Assemble differential pinion shaft lock pin. Peen metal of differential case over roll pin to lock in two places 180 degrees apart.
Make sure flange face of the differential case is free of nicks or burrs. Assemble ring gear to differential case. Line up holes of the ring gear with those of the differential case. Use new ring gear bolts. Draw up bolts alternately and evenly. Tighten grade 8 ring gear bolts to 136-162 Nm (100-120 lb-ft). Tighten grade 9 ring gear bolts to 176-190 Nm (130-140 lb-ft).
Place the inner axle shaft oil seals (3254) in the axle tube housing. Press both axle shaft oil seals in at the same time with an appropriate installation tool. Make sure axle shaft oil seals are pressed in straight and not cocked in the bore. Coat the lips of the axle shaft oil seals with High Temperature 4x4 Front Axle and Wheel Bearing Lubricant E8TZ-19590-A or equivalent meeting Ford specification ESA-M1C198-A.
Install Dummy Differential Bearings Tool D81T-4222-DR or equivalent onto differential case. Remove all nicks, burrs, dirt, etc. from hubs to allow bearings to rotate freely.
NOTE: Dial indicator should have a minimum travel capability of 5.08mm (0.200 inch).
Assemble differential case into carrier (less pinion). Mount Dial Indicator with Bracketry TOOL-4201-C or equivalent as shown. Locate tip of indicator on flat surface of one of the ring gear bolt spot faces.
Force differential (4026) as far as possible toward the indicator. With force still applied, set indicator at zero.
Force the differential as far as it will go in the opposite direction. Repeat these steps until you have obtained the same reading. Record the reading of the indicator. This will be the total amount of differential bearing shims (4067) required (less preload) and will be calculated later during assembly.
NOTE: Ring gears and pinions are supplied in matched sets only. Matching numbers are etched on both the pinion and ring gear for verification. If a new gear set is being used, verify the numbers of each pinion and ring gear before proceeding with assembly.
After making sure the readings are correct, remove indicator and differential from housing. Do not remove master bearings from differential case at this time.
The reading obtained in Step 13 is the total differential case end play which will be needed in Assembly of Differential into Housing in the Disassembly and Assembly portion of this section.
The distance from the centerline of the ring gear to the backface of the pinion is 127mm (5.000 inch).
On the button of each pinion, there is etched a plus (+) number, a minus (-) number, or a zero (0) number which indicates the best running position for each particular gear set. This dimension is controlled by the shimming behind the inner pinion bearing cup.
NOTE: Do not use the button of the pinion for pinion positioning. The button of the pinion is no longer a ground surface.
For example, if a pinion is etched a plus m+8 (+3), this pinion would require 0.08mm (0.003 inch) less shims than a pinion etched "0". This means by removing shims, the mounting distance of the pinion is increased, which is what m+8 (+3) indicates. Or if a pinion is etched m-8 (-3), we would want to add 0.08mm (0.003 inch) more shims than would be required if the pinion were etched "0". By adding 0.08mm (0.003 inch) shims, the mounting distance of the pinion was decreased, which is what m-8 (-3) indicated.
If the old gear set is to be reused, measure the old shim pack and build a new shim pack to this same dimension. If a baffle and oil slinger is used in the axle, it is considered as part of the shim pack.
To change the pinion adjustment, shims are available in thicknesses of 0.08, 0.13 and 0.25mm (0.003, 0.005 and 0.010 inch).
NOTE: If baffle or oil slinger is bent or mutilated, it should be replaced.
Measure each shim separately with a micrometer and add together to get the total shim pack thickness from the original buildup.
If a new gear set is being used, notice the (+) or (-) etching on both the old and new pinion and adjust the thickness of the new shim pack to compensate for the difference of these two figures.
For example, if the old pinion reads m+5 (+2) and the new pinion is m-5 (-2), add 0.10mm (0.004 inch) shims to the original shim pack.
| Old Pinion Marking | New Pinion Marking (English) | ||||||||
|---|---|---|---|---|---|---|---|---|---|
| -4 | -3 | -2 | -1 | 0 | +1 | +2 | +3 | +4 | |
| +4 | +0.008 | +0.007 | +0.006 | +0.005 | +0.004 | +0.003 | +0.002 | +0.001 | 0 |
| +3 | +0.007 | +0.006 | +0.005 | +0.004 | +0.003 | +0.002 | +0.001 | 0 | -0.001 |
| +2 | +0.006 | +0.005 | +0.004 | +0.003 | +0.002 | +0.001 | 0 | -0.001 | -0.002 |
| +1 | +0.005 | +0.004 | +0.003 | +0.002 | +0.001 | 0 | -0.001 | -0.002 | -0.003 |
| 0 | +0.004 | +0.003 | +0.002 | +0.001 | 0 | -0.001 | -0.002 | -0.003 | -0.004 |
| -1 | +0.003 | +0.002 | +0.001 | 0 | -0.001 | -0.002 | -0.003 | -0.004 | -0.005 |
| -2 | +0.002 | +0.001 | 0 | -0.001 | -0.002 | -0.003 | -0.004 | -0.005 | -0.006 |
| -3 | +0.001 | 0 | -0.001 | -0.002 | -0.003 | -0.004 | -0.005 | -0.006 | -0.007 |
| -4 | 0 | -0.001 | -0.002 | -0.003 | -0.004 | -0.005 | -0.006 | -0.007 | -0.008 |
| Old Pinion Marking | New Pinion Marking (Metric) | ||||||||
|---|---|---|---|---|---|---|---|---|---|
| -10 | -8 | -5 | -3 | 0 | +3 | +5 | +8 | +10 | |
| +10 | +0.20 | +0.18 | +0.15 | +0.13 | +0.10 | +0.08 | +0.05 | +0.03 | 0 |
| +8 | +0.18 | +0.15 | +0.13 | +0.10 | +0.08 | +0.05 | +0.03 | 0 | -0.03 |
| +5 | +0.15 | +0.13 | +0.10 | +0.08 | +0.05 | +0.03 | 0 | -0.03 | -0.05 |
| +3 | +0.13 | +0.10 | +0.08 | +0.05 | +0.03 | 0 | -0.03 | -0.05 | -0.08 |
| 0 | +0.10 | +0.08 | +0.05 | +0.03 | 0 | -0.03 | -0.05 | -0.08 | -0.10 |
| -3 | +0.08 | +0.05 | +0.03 | 0 | -0.03 | -0.05 | -0.08 | -0.10 | -0.13 |
| -5 | +0.05 | +0.03 | 0 | -0.03 | -0.05 | -0.08 | -0.10 | -0.13 | -0.15 |
| -8 | +0.03 | 0 | -0.03 | -0.05 | -0.08 | -0.10 | -0.13 | -0.15 | -0.18 |
| -10 | 0 | -0.03 | -0.05 | -0.08 | -0.10 | -0.13 | -0.15 | -0.18 | -0.20 |