Assembly of Differential Into Housing

Ring Gear and Pinion Backlash

1. Place differential (4026) into housing. Differential master bearings should still be assembled to differential case (4204).

2. Set up Dial Indicator with Bracketry TOOL-4201-C or equivalent. Force ring gear into mesh with the pinion. Rock ring gear to allow the teeth of the gears to mesh. With force still applied to the differential case, set indicator at zero.

   
   
   
   
   

3. NOTE: This reading will be the necessary amount of differential bearing shims (4067) required between the differential case and differential bearings on the ring gear side.

   Force the differential case (ring gear) away from the pinion gear to obtain an indicator reading. Repeat until the same reading is obtained each time.

4. Remove indicator and differential case from the carrier.

5. Remove master bearings from differential case.

   
   
   
   
   

6. As determined in Step 3, place the required amount of differential bearing shims on the ring gear hub of the differential case. For example, if the reading in Step 3 was 1.14mm (0.045 inch), place 1.14mm (0.045 inch) of differential bearing shims on the hub of the ring gear side of the differential case.

7. Install the bearing cone on the ring gear side of the differential case. Drive the bearing onto the hub using Differential Bearing Cone Replacer D81T-4221-A or equivalent as shown.

8. To determine the correct amount of differential bearing shims to be placed on the hub of the drive pinion side of the differential case, subtract the reading obtained in Step 3 from the total differential case end play. Total differential case end play was determined under Steps 10 and 11 of Differential Case, Assembly in the Disassembly and Assembly portion of this section. When this amount is determined, add 0.36mm (0.015 inch) to the amount. This is the required amount of differential bearing shims to be placed on the hub of the drive pinion side of the differential case.

   For example, total differential case end play was 2.30mm (0.091 inch). The reading in Step 3 of this procedure was 1.14mm (0.045 inch), which, when subtracted from 2.30mm (0.091 inch), gives 1.16mm (0.046 inch). 0.36mm (0.015 inch) is added to give 1.52mm (0.061 inch) of differential bearing shims to be placed on the hub of the drive pinion side of the differential case.

9. Place the required amount of differential bearing shims on the hub of the drive pinion side of the differential case.

10. Install the bearing cone on the hub of the drive pinion side of the differential case using Differential Bearing Cone Replacer D81T-4221-A or equivalent. Place Step Plate Adapter D80L-630-7 or equivalent on the ring gear side bearing to protect the bearing during installation of the drive pinion side bearing.

    
    
    
    
    

11. Place the bearing on the drive pinion side hub and drive it on using Differential Bearing Cone Replacer D81T-4221-A or equivalent.

12.  CAUTION: Do not spread carrier over 0.38mm (0.015 inch).

    Install Differential Housing Spreader TOOL-4000-E or equivalent and indicator to carrier. Remove indicator.

    
    
    
    
    

13. Assemble differential bearing cup (4222) to differential bearing cones.

14. NOTE: Avoid nicking the teeth of the ring gear and pinion during assembly.

    Install differential into carrier. Use a rawhide hammer to seat differential into crossbore of carrier.

    
    
    
    
    

15. Remove the spreader from the differential case.

16. Install bearing caps. Make sure the letters stamped on the caps correspond with those on the carriers. Tighten bearing capscrews to 109-122 Nm (80-90 lb-ft).

    
    
    
    
    

17. Check ring gear and pinion backlash in three equally spaced points with dial indicator.

    1. Backlash tolerance is 0.13-0.23mm (0.005-0.009 inch) and cannot vary more than 0.05mm (0.002 inch) between points checked.
    2. High backlash is corrected by moving the ring gear closer to the pinion.
    3. Low backlash is corrected by moving ring gear away from the pinion.
    4. These corrections are made by switching differential bearing shims from one side of the differential case to the other.
       
       
       
       

18. Obtain a gear tooth contact pattern. Refer to Gear Tooth Contact Pattern Check in the Disassembly and Assembly portion of this section prior to complete reassembly.

19. The cover face of the carrier and the flat surface of the axle housing cover (4033) must be free of any oil film or foreign material.

    Apply RTV Silicone Rubber Sealer D6AZ-19562-AA (clear) or -BA (black) sealant or equivalent meeting Ford specifications ESB-M4G92-A or ESE-M4G195-A to surface of the axle housing cover. Make sure the sealer bead (3.18-6.35mm [1/8 to 1/4 inch] high and wide) is laid on the inside of the cover screw holes. The bead is not to pass through the holes or outside of the holes.

    
    
    
    
    

20. Install two cover screws into axle housing cover at 8 o'clock and 2 o'clock positions. Use these two holes to guide axle housing cover into position on the carrier.

21. NOTE: Allow one hour curing time before filling carrier with the proper amount of specified lubricant and vehicle operation.

    Install remaining screws. Tighten alternately and evenly. Tighten screws to 41-54 Nm (30-40 lb-ft).

22. Install the axle shafts as described under Axle Shaft in the Removal and Installation portion of this section.

23. Install front axle to vehicle. Refer to Axle, Front in the Removal and Installation portion of this section.