DISASSEMBLY AND ASSEMBLY -...

205-03-1 205-03-1Front Drive Axle/Differential — Ford 8.8-Inch Ring Gear

DISASSEMBLY AND ASSEMBLY

Special Tool(s)Axle — Front Drive Carrier Bearing Replacer205-D044 (D81T-4221-A) orSpecial Tool(s) Equivalent2-Jaw Puller205-D072 (D97L-4221-A)

Clutch Housing AlignmentAdapter308-021 (T75L-4201-A)Aligning Adapter205-105 (T76P-4020-A3)

Companion Flange HoldingTool205-126 (T78P-4851-A)Bearing Cup Remover308-047 (T77F-1102-A)

Companion Flange Replacer205-002 (TOOL-4858-E)Bearing Preload Tool205-S337 (T93P-4220-AR)

Dial Indicator100-D005 (D78P-4201-G) orEquivalentBlind Hole Puller Set303-DS005 (D80L-100-A) orEquivalentDifferential Carrier Spreader205-001 (TOOL-4000-E) orEquivalentBracketry for Dial Indicator100-D004 (D78P-4201-F) orEquivalentDifferential Side BearingReplacer205-010 (T57L-4221-A2)(Continued)

(Continued)Copyright 2002, Ford Motor CompanyLast updated: 3/24/2004 2003 F150, 1/2003


DISASSEMBLY AND ASSEMBLY (Continued)

Special Tool(s) Special Tool(s)

Gauge Block Housing Spreader Adapters205-110 (T76P-4020-A10) 205-335 (T93P-4000-A) (RH)

Gauge Disc Impact Slide Hammer205-129 (T79P-4020-A18) 100-001 (T50T-100-A)

Gauge Tube Inner Axle Shaft Bearing205-336 (T93P-4020-A) Replacer205-367 (T96T-3N106-A)

Handle Left Master Bearing205-111 (T76P-4020-A11) 205-338 (T93P-4222-A)

Handle Pinion Bearing Cone Replacer205-153 (T80T-4000-W) 205-005 (T53T-4621-C)

Holding Fixture Pinion Bearing Cup Replacer307-003 (T57L-500-B) 205-024 (T67P-4616-A)

Housing Spreader Adapter Pinion Thread Protector205-368 (T96T-4000-A) (LH) 205-460

(Continued) (Continued)

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Special Tool(s) Special Tool(s)

Pinion Seal Replacer Axle Shaft Seal Replacer205-133 (T79P-4676-A) 205-366 (T96T-3B112-A)

Right Master Bearing Needle Bearing Replacer205-339 (T93P-4222-B) 205-362 (T96T-1244-A)

Screw Outer Shaft Deflector Replacer205-109 (T76P-4020-A9) 205-365 (T96T-3A379-A)

Step PlateMaterial205-D061 (D83T-4205-C2)

Item Specification

Silicone Gasket and WSE-M4G323-A4SealantF7AZ-19554-EAPremium Long Life ESA-M1C75-BGreaseUniversal Bearing Puller XG-1-C205-055 (T71P-4621-B) SAE 75W-90 Premium WSP-M2C201-A4x4 Front Axle LubricantXY-75W90-TQLDisassembly

Vacuum Pump Kit 1. Remove the front drive axle assembly. For416-D002 (D95L-7559-A) or additional information, refer to Axle AssemblyEquivalent — Front Drive in this section.2. Remove the vacuum control shield.

• Remove the three bolts.• Remove the shield.(Continued)

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3. Remove the differential housing cover. 6. Remove the E-ring.1 Remove the drain plug.2 Drain the fluid.3 Remove the bolts.4 Remove the differential housing cover.

7. Disconnect the front axle actuator motorassembly.1 Fully extend the actuator motor shaft.2 Plug the vacuum ports.3 Pull outward on the front axle actuator4. CAUTION: The fixture mounting bolts motor assembly.must have the minimum specified thread 4 Push the front axle actuator motor assemblyengagement in the carrier. to disconnect the shift lever from the slot inInstall the special tool. the actuator motor shaft.

5. Unseat the clutch shaft rod boot.

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8. Remove the clutch shaft rod boot, and the frontaxle actuator motor assembly.1 Remove the clutch shaft rod boot.2 Remove the front axle actuator motorassembly.

12. Remove the axle clutch gear.1 Push the axle shaft inward, and remove thesnap ring.2 Remove the axle clutch gear.

9. Remove the axle housing tube.

13. Remove the steel thrust washer and the tangedthrust washer.10. Secure the axle housing tube in a vise.

11. Remove the gasket from the sealing groove andflange face.2003 F150, 1/2003



14. Remove the axle shaft.

18. CAUTION: Be careful not to damagethe seal or bearing surfaces.15. Using the special tools, remove the inner If necessary, remove the axle shaft dustbearing. deflector.

16. Reposition the axle housing tube in the vise, 19. Remove the thrust washer.and remove the axle shaft dust seal.

17. Using the special tools, remove the outerbearing.

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20. Remove the axle cluster gear shaft. 23. NOTE: There is enough clearance in thecasting to remove the manual shaft retainingpin.If necessary, remove the shift lever and theclutch fork.1 Drive the manual shaft retaining pin throughthe clutch fork.2 Remove the shift lever and the clutch fork.

21. CAUTION: Use a vise with soft jaws.Using the special tool, remove the pilot bearingassembly from the axle cluster gear shaft.1 Position the axle cluster gear shaft in thevise.2 Using the special tool, remove the pilotbearing assembly. 24. Remove and discard the O-ring.

22. Lift the shift lever, and remove the coupler shiftselector gear.

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25. Remove the axle shaft. 28. If necessary, adjust the special tool to provideclearance for the shift lever.1 Remove the snap ring.2 Remove the axle shaft.

29. Install the special tools.• Position the adapter tip in the spreader26. CAUTION: The housing spreader adapter hole.adapter bolts must have the minimumspecified thread engagement in the carrier.

Install the special tools.

27. Position the special tool on the spreaderadapters.

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30. CAUTION: Overspreading can damage 32. CAUTION: Use wood blocks to avoidthe axle housing. axle housing damage.Spread the axle housing to the specification. Remove the differential assembly from the axlehousing.1 Adjust the special tool to zero. 1 Position the wood blocks.2 Tighten the housing spreader screw tospread the axle housing to the specification. 2 Position and push down on the two prybars.3 Remove the Dial Indicator. 3 Remove the differential assembly.

4 Remove the special tool.

31. CAUTION: Mark the differentialbearing caps Top or Bottom and LH or RHappropriately before removing them. Always 33. Index-mark the axle universal joint flange to theinstall the bearing caps in their original place pinion stem.and position.Mark and remove the differential bearing caps.1 Remove the bolts.2 Remove the differential bearing caps.

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34. Install the special tool, and loosen, but do notremove the pinion nut.

38. Discard the drive pinion collapsible spacer.35. With the pinion nut still engaged by a fewthreads, use the special tool to separate the axleuniversal joint flange from the pinion gear.

39. CAUTION: Do not damage the carrierhousing while removing the pinion seal.Remove the pinion seal and slinger.• Pry up on the seal flange. Install grippingpliers, and strike with a hammer to remove36. Remove the nut and the flange. the seal.37. Using the special tool and a soft hammer,remove the pinion gear.

1 Install the special tool.2 Hold the pinion gear inside the carrierhousing.3 Using a soft face hammer, remove thepinion gear from the carrier housing.

40. Remove the outer pinion bearing.

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41. Using the special tools, remove the inner pinion 44. Using the special tool and a suitable press,bearing cup. remove the pinion bearing.

42. NOTE: The pinion bearing oil baffle aids in 45. NOTE: A drive pinion bearing adjustment shimbearing lubrication. Normally, it is not sits under the pinion bearing. Use a micrometernecessary to remove the baffle. to measure the shim thickness. Record themeasurement for comparison to the shim gaugeIf necessary, remove the pinion bearing oil reading taken prior to installing the pinionbaffle. bearing.Remove and measure the drive pinion bearingadjustment shim.

43. Remove the outer pinion bearing cup bytapping alternately on each side to prevent thecup from cocking.

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46. Remove the ten bolts and the ring gear. 2. Using the special tool, install the baffle.• Use a drift punch to separate the ring gearfrom the differential case.

3. NOTE: Always install new pinion bearingswhen installing new pinion bearing cups.47. Using the special tools, remove the differential Lightly oil the new pinion bearing cups andbearings. pinion bearings with axle lubricant.

4. Using the special tool, install the bearing cups.

Assembly

1. CAUTION: Do not omit the pinionbearing oil baffle; bearing failure can result.If removed, position the baffle on the specialtool.

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5. NOTE: You must use the pinion bearingsassembled in this procedure step at finalassembly.Assemble and position the special tools and thepinion bearings in the carrier housing.1 Position the Screw.2 Position the Aligning Adapter.3 Position the pinion bearing.4 Position the Gauge Disc.5 Position the Gauge Block.6 Position the pinion bearing. 7. NOTE: Offset the Gauge Block to obtain an7 Thread on the Handle. accurate reading.

Rotate the Gauge Block several half-turns tomake sure the pinion bearings seat correctly,and position the Gauge Block.

8. Install the special tool.1 Position the special tool.2 Install the differential bearing caps.3 Install the bolts.

6. NOTE: This step duplicates final pinionbearing preload.Tighten the special tool to the specification tosimulate bearing preload.

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9. NOTE: Use only flat, clean drive pinion 11. Place a new drive pinion collapsible spacer onbearing adjustment shims. the pinion stem.NOTE: Selection of a shim that is too thickresults in a deep tooth contact at final assemblyof integral axle assemblies. Do not attempt toforce the shim between the Gauge Block andthe Gauge Tube. A slight drag indicates correctshim selection.Use a drive pinion bearing adjustment shim as agauge for shim selection.• Check the adjustment shim thicknessbetween the Gauge Block and the GaugeTube.• After determining the correct shimthickness, remove the special tools. 12. Install the outer pinion bearing.

10. NOTE: You must use the same pinion bearings 13. Install the slinger.from the previous steps.Install the pinion bearing.• Place the drive pinion bearing adjustmentshim on the pinion gear.• Using a suitable press and the special tool,press the pinion bearing until it is firmlyseated on the pinion gear.

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14. NOTE: Coat the lips of the pinion seal with 18. CAUTION: Never install the axleaxle lubricant. universal joint flange with a hammer.Place the pinion seal on the special tool. NOTE: Disregard the scribe marks if installinga new flange.Align the index-marks and position theuniversal joint flange on the drive pinion.

15. Place the special tool and seal in the pinion sealbore and drive the seal into place.19. Using the special tool, install the axle universaljoint flange.

16. Lightly lubricate the pinion gear splines withaxle lubricant.17. Position the pinion gear in the housing. 20. Apply a small amount of lubricant to thewasher side of the new pinion nut, and installthe nut.

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21. CAUTION: Do not loosen the pinion 22. CAUTION: Use extreme care not tonut to reduce preload under any damage the aluminum differential carriercircumstance. If it is necessary to reduce housing while performing the followingpreload, install a new drive pinion collapsible procedure steps.spacer and pinion nut. CAUTION: The special tools areInstall the special tool, and tighten the pinion marked LH and RH. Install themnut. Refer to the torque specifications in the accordingly.Specifications portion of this section. Install the special tools.• Rotate the pinion gear occasionally to makesure the pinion bearings are seatingcorrectly. Take frequent pinion bearingtorque preload readings by rotating thepinion gear with an Nm (inch/pound) torquewrench.

23. Install the differential case with the MasterBearings in the differential carrier.

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24. NOTE: Repeat this step until you obtain aconsistent reading.Measure the total end play.1 Position the special tools.2 Position the indicator tip on the machinedsurface and adjust it to measure full travel.3 Push the differential case left and right (asfar as possible).4 Measure the total end play and record thereading on the Differential Bearing ShimSelection Procedure Worksheet, Line A, inthis procedure. 27. Install the ring gear.

1 Position three bolts to align the holes in thering gear and the differential case.2 Using a suitable press, install the ring gear.

25. Remove the special tools and the differentialcase.28. Install the remaining bolts.

26. Use a fine flat file to remove any burrs or nicksfrom the ring gear mounting surface.

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29. Remove three adjacent bolts.

33. Move the ring gear away from the pinion gearas far as possible. Record the reading on theDifferential Bearing Shim Selection Procedure30. CAUTION: Position the three empty Worksheet, Line B, in this procedure.bolt holes downward.Position the differential case with the specialtools into the differential carrier housing.

34. Remove the special tools.31. Position the special tools.

32. Push and rock the ring gear into mesh with thepinion gear (zero backlash) and adjust thespecial tool to zero.2003 F150, 1/2003



35. Remove the differential case and the specialtools.

38. Measure the differential bearing stand height.1 Invert the special tool and bearing assemblyin the vise.36. NOTE: Measure both of the differential bearing 2 Use a depth micrometer to measure andstand heights prior to installing them on the record the differential bearing stand height.differential case.

X Repeat the procedure for the otherNOTE: Mark the left and right differential bearing.bearings before measuring them.Clamp the special tool base in a soft jawed visewith the bearing mounting surface above thesurface of the vise.

39. Select appropriate differential bearing shims.

37. Position the differential bearing assembly in thespecial tool, and tighten the tool.Differential Bearing Shim Selection Chart

8.8-inch Aluminum Axle Example Actual

Line-A End play without ring gear 0.498Line-B End play with ring gear (ring -0.245 minus (-)gear side)Line-C Subtract Line-B from Line-A, 0.253also record on Line C, below

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Left Differential Bearing Height Right Differential Bearing Height

Example Actual Example Actual8.8-inch Aluminum Axle

Master bearing height 0.8695 0.8695 0.8695 0.8695Line-D Actual bearing height -0.8478 minus (-) -0.8491 minus (-)Line-E Difference 0.0217 0.0204

Left Side Right Side

Example Actual Example Actual8.8-inch Aluminum Axle 8.8-inch Aluminum Axle

Line-B End play 0.2450 + Line-C End play 0.2530 + Line-E Bearing height +0.0217 Line-E Bearing height +0.0204TOTAL Lines B and E 0.2667 -0.006 TOTAL Lines C and E 0.2734 +0.020 Backlash (subtract) -0.0060 Backlash/preload (add) +0.020Initial thicknessa 0.2607 Initial thickness 0.2934Final shim thickness — left 0.261 Final shim thickness — 0.293righta Round off initial thickness to the nearest shim thickness as in example for final shim thickness.

Differential Shim Size Chart40. Select the appropriate shim by the thickness orNumbers ofthe stripe color. Dimension AStripes and

mm In.Color CodeBacklash Change Thickness ChangeRequired Required 2— C-COAL 7.7978-7.8105 0.3070-0.3075 1— C-COAL 7.7470-7.7597 0.3050-0.3055mm In. mm In. 5— BLU 7.6962-7.7089 0.3030-0.30350.025 0.001 0.050 0.002 4— BLU 7.6454-7.6581 0.3010-0.3015 0.050 0.002 0.050 0.002 3— BLU 7.5946-7.6073 0.2990-0.2995 0.076 0.003 0.101 0.004 2— BLU 7.5458-7.5565 0.2970-0.2975 0.101 0.004 0.152 0.006 1— BLU 7.4930-7.5057 0.2950-0.2955 0.127 0.005 0.152 0.006 5— PINK 7.4422-7.4549 0.2930-0.2935 0.152 0.006 0.203 0.008 4— PINK 7.3914-7.4041 0.2910-0.2915 0.177 0.007 0.254 0.010 3— PINK 7.3406-7.3533 0.2890-0.2895 0.203 0.008 0.254 0.010 2— PINK 7.2898-7.3025 0.2870-0.2875 0.228 0.009 0.304 0.012 1— PINK 7.2390-7.2517 0.2850-0.2855 0.254 0.010 0.355 0.014 5— GRN 7.1882-7.2009 0.2830-0.2835 0.279 0.011 0.355 0.014 4— GRN 7.1374-7.1501 0.2810-0.2815 0.304 0.012 0.406 0.016 3— GRN 7.0866-7.0993 0.2790-0.2795 0.330 0.013 0.457 0.018 2— GRN 7.0358-7.0485 0.2770-0.2775 0.335 0.014 0.457 0.018 1— GRN 6.9850-6.9977 0.2750-0.2755 0.381 0.015 0.508 0.020 5— WH 6.9342-6.9469 0.2730-0.2735 4— WH 6.8834-6.8961 0.2710-0.2715 3— WH 6.8326-6.8453 0.2690-0.2695 2— WH 6.7818-6.7945 0.2670-0.2675 1— WH 6.7310-6.7437 0.2650-0.2655 5— YEL 6.6802-6.6929 0.2630-0.2635 4— YEL 6.6294-6.6421 0.2610-0.2615 3— YEL 6.5786-6.5913 0.2590-0.2595 2— YEL 6.5278-6.5405 0.2570-0.2575 1— YEL 6.4770-6.4897 0.2550-0.2555 5— ORNG 6.4262-6.4389 0.2530-0.2535 4— ORNG 6.3754-6.3881 0.2510-0.2515 3— ORNG 6.3246-6.3373 0.2490-0.2495 2— ORNG 6.2738-6.2865 0.2470-0.2475 1— ORNG 6.2223-6.2357 0.2450-0.2455 2— RED 6.1722-6.1849 0.2430-0.2335 1— RED 6.1214-6.1341 0.2410-0.2415

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43. NOTE: Make sure the indicator needle is in thespreader adapter hole.Install the special tools.

41. Install the three bolts.

44. CAUTION: Overspreading can damagethe axle housing.Spread the axle housing to the specification.• Remove the Dial Indicator.

42. CAUTION: Press against the bearinginner cone only.Using a suitable press and the special tool,install the differential bearings.1 Position the appropriate differential bearing(RH or LH).2 Using a suitable press and the special tool,install the differential bearing.• Repeat the procedure for the otherdifferential bearing.

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47. Install the bearing caps in their original45. CAUTION: Never attempt to drive the positions and tighten with the housing stilldifferential bearing shim in place. Permanent spread.damage to the machined axle housingsurfaces can occur. 1 Position the bearing caps.If removed, position the differential bearing 2 Install the bolts.shims. 3 Remove the special tool.1 Apply a light coating of Premium Long LifeGrease to one side of the differentialbearing shims to help hold them in place.2 Position the differential bearing shims.

48. Install the special tool.

46. NOTE: Push the differential case downward tofully seat the differential bearing cups in theaxle housing.Position the differential case assembly.1 Position the differential bearing cups on thedifferential bearings.2 Lower the differential case assembly inplace between the differential bearing shims.

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49. Measure the ring gear backlash at four places toobtain a consistent reading.1 Mount the special tools on the indicatorbase.2 Position the indicator needle and zero theindicator.3 Turn the ring gear without turning thepinion gear and record the measurement.

52. Liberally lubricate the axle shaft shift lever, andinstall a new O-ring.• Use Ford Silicone Brake Caliper Grease andDielectric Compound.

50. NOTE: If the backlash is not within thespecifications, correct it by increasing thethickness of one differential bearing shim anddecreasing the thickness on the otherdifferential bearing shim by the same amount.To increase the backlash, install a thickerdifferential bearing shim and a thinnerdifferential bearing shim as shown. 53. Install the axle shaft shift lever.

1 Position the clutch fork.2 Install the axle shaft shift lever.

X Align the manual shaft retaining pinholes.

51. To decrease the backlash, install a thickerdifferential bearing shim and a thinnerdifferential bearing shim as shown.

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54. Install the manual shaft retaining pin flush with 57. Insert the axle cluster gear shaft through thethe axle shaft shift lever. coupler shift selector gear and engage thesplines.

55. Lift the axle shaft shift lever, and position thecoupler shift selector gear, tapered end 58. Coat the thrust washer with grease, and positiondownward, into the clutch fork. it on the axle cluster gear shaft.• Use Premium Long Life Grease.

56. Using the special tools, install the pilot bearingassembly into the axle cluster gear shaft.

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61. Using the special tools, install the axle shaft59. CAUTION: The arrow marked dust seal.‘‘Inboard’’ on the Needle Bearing Replacertool must point toward the axle housing • Make sure the axle shaft dust seal flange iswhen installing the inner bearing. flush with the axle housing tube.Using the special tools, install the inner bearing.1 Position the axle housing tube in a vise.2 Position the inner bearing.3 Using the special tools, install the innerbearing.

62. If removed, position the axle shaft dustdeflector for installation.1 Position the axle bearing seal plate on thepress bed.2 Position the special tool.3 Position the axle shaft dust deflector.60. CAUTION: The arrow marked‘‘Outboard’’ on the Needle Bearing Replacertool must point toward the axle housingwhen installing the outer bearing.

NOTE: When the tool flange bottoms out onthe tube flange, bearing installation is correct.Using the special tools, install the outer bearing.1 Position the axle housing tube in the vise.2 Position the outer bearing.3 Using the special tools, install the outerbearing.

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63. If removed, use a suitable press to press the 67. Install the axle clutch gear.axle shaft dust deflector on the axle shaft.

68. Push in on the axle shaft and install a new snap64. Insert the axle shaft into the axle housing tube. ring.

65. Lubricate the steel thrust washer.• Use Premium Long Life Grease.

66. Install the tanged thrust washer and the steelthrust washer.

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69. CAUTION: Remove all of the oldliquid gasket, and make sure the machinedsurfaces are free of oil before applying thenew silicone rubber.CAUTION: Install the axle housingtube within 15 minutes of applying thesilicone, or it will be necessary to removeand reapply new sealant. If possible, allowone hour before filling with lubricant tomake sure the silicone has cured.CAUTION: Do not allow any siliconerubber to squeeze inside during assembly. 72. Insert the axle shaft and engage it with the sideFill the groove with Silicone Gasket and gear.Sealant.

73. NOTE: Do not reuse the old snap ring.70. Assemble the axle housing tube. Push in on the axle shaft and install a new snap• Align the bolt holes and position the axle ring.housing tube.• Position the axle identification tag.• Install the bolts.

71. Examine the axle shaft seal and bearing surfacefor damage. If necessary, polish the bearingsurface with fine crocus cloth.2003 F150, 1/2003



74. Install the clutch shaft rod boot. 77. Seat the clutch shaft rod boot in the slot in theactuator housing.1 Fully extend the actuator motor shaft andplug the vacuum ports. • Remove the plugs from the vacuum ports.2 Position the front axle actuator motorassembly.3 Install the clutch shaft rod boot.

78. NOTE: Install a new vacuum motor if anyvacuum leakage is observed.NOTE: With the lever moved outboard, theaxle is engaged and the axles will turn opposite75. With the actuator motor shaft fully extended of each other. With the lever moved inboard,and the vacuum ports plugged, engage the shift the axle is disengaged and the axles will turnlever. freely of each other.Verify the front axle actuator motor assemblyoperation (engage).• Using the special tool, apply vacuum to theouter vacuum port to move the shift leveroutboard. Rotate one axle shaft to verifyengagement.

76. Seat the front axle actuator motor assembly andinstall the E-ring.

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79. Verify the front axle actuator motor assembly 82. Install the differential housing cover.operation (disengage). 1 Position the differential housing cover.• Using the special tool, apply vacuum to the 2 Install the bolts.inner vacuum port to move the shift leverinboard. Rotate one axle to verifydisengagement.

83. Fill the differential carrier housing, and installthe fill plug, using front axle lubricant.• Be sure to tighten both the drain and fill80. Remove the axle assembly from the Holding plugs.Fixture and place it on the bench.

81. CAUTION: Remove all of the oil liquidgasket, and make sure the machined surfacesare free of oil before applying the newsilicone rubber.CAUTION: Install the differentialhousing cover within 15 minutes of applyingthe silicone, or it will be necessary to removeand reapply new sealant. If possible, allowone hour before filling with lubricant tomake sure the silicone has cured.

Fill the sealing groove on the differentialhousing cover with Silicone Gasket and Sealant. 84. Install the vacuum control shield.• Install the shield.• Install the bolts and the torque bolts.

85. Install the front drive axle assembly. Foradditional information, refer to Axle Assembly— Front Drive in this section.

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