Drive Axle - Full Floating Ford Bronco II I

AXLE RATIO & IDENTIFICATION

The steel cover plate has a unique shape which allows positive identification of Dana axles on any model vehicle. Axle model can also be determined by measuring the diameter of ring gear. See MODEL IDENTIFICATION BY RING GEAR SIZE table.

A metal tag on rear axle is stamped with gear ratio, part numbers and limited slip identification. To determine drive axle ratio, refer to MODEL IDENTIFICATION BY RING GEAR SIZE table.

Dana Housing Cover Gasket. Scheme 12

MODEL IDENTIFICATION BY RING GEAR SIZE

Exploded View Of Dana Full-Floating Axle Assembly. Scheme 13

Note. One-piece differential case shown.

DESCRIPTION

The axle assembly is integral carrier type with Hypoid gear ring and pinion. Stamped steel cover is removable for inspection and repair of differential.

"Full-floating" refers to an axle in which vehicle loads are carried by axle housings. Axle shafts of "full-floating" assemblies may be removed without disturbing wheel bearings, which are tapered roller type. These bearings ride in hub to which axle shaft flange is bolted. Inner races of bearings ride on machine surfaces of axle housing.

Drive pinion depth, pinion bearing preload and differential side bearing preload are all set by shims. Other than special FWD components, front and rear axles are identical. All 4WD front drive axles are "full-floating".

On Ford Motor Co. F350 (4WD) models, the front axle has an open yoke design. Other than components required for front wheel drive, these axles are mechanically identical to the rear axle.

See LOCKING HUBS - AUTOMATIC and 4WD STEERING KNUCKLE articles for removal and installation procedures for these front drive axle component parts.

REMOVAL & INSTALLATION

Note. These axle models are used by several vehicle manufacturers. Tool numbers called out for procedures specific to make of vehicle will be tool number as used by individual vehicle manufacturer. Tool numbers called out for general procedures, such as OVERHAUL and PINION FLANGE & SEAL , will be tool number used by Dana. These tools are available from Miller Special Tools, which uses same numbering system as Dana.

Removal

1. Raise vehicle on a twin-post hoist. Remove front tires and hubs. See «HUB & BEARINGS»(/ford/bronco-ii/i-1984-1990/remont/differentials-drive-axles/#drive-axle-full-floating__hub-bearings) . Remove brake caliper and rotor assembly.
2. Remove washers and nuts securing stabilizer links to stabilizer bar. Disconnect stabilizer links from stabilizer bar. If required, remove "U" bolts and nuts retaining stabilizer bar and mounting brackets to axle. Remove stabilizer bar.
3. Remove 2 nuts and "U" bolts from front axle "U" joint flange and disconnect axle from front axle pinion flange. Using wire, secure driveshaft to frame. Disconnect vent tube at axle housing. Plug vent fitting.
4. On right side of vehicle, remove nut and bolt and disconnect tracking bar from right spring cap. Carefully lower twin-post hoist until vehicle is about 3 feet from floor. Position safety stands on front leaf springs about halfway between front axle leaf spring and rear mounting shackle. Lower vehicle so springs rest on safety stands. CAUTION: Ensure vehicle is securely supported.
5. Support axle under differential carrier with a suitable jack. Remove "U" bolts and nuts securing axle to spring. Carefully lower axle from vehicle.

Installation

1. With axle supported under differential carrier by a transmission jack, carefully raise axle to vehicle. Ensure retaining bolt head protruding from leaf spring plate seats in recessed portion of axle spring mounting plate.
2. Install and tighten nuts, "U" bolts and spring caps securing axle to spring. Raise vehicle and remove safety stands. Connect driveshaft to front axle pinion flange. To complete assembly, reverse removal procedure.

HUB & BEARINGS

Note. Although hub bearings are lubricated by flow of axle oil, all manufacturers require hub bearings be packed with high temperature, multipurpose grease before installation.

Removal (All Models Front & Rear)

1. Raise vehicle and support securely. Remove wheels and axle shaft or hub driving gear. On front axles, bend back ears on nut retainer. Remove outer lock nut and locking ring. On rear axles, pry locking pin or wedge out from adjusting nut. DO NOT move adjusting nut before locking wedge is removed.
2. On all axles, remove bearing adjusting nut, thrust washer (if equipped) and outer hub wheel bearing. Remove hub with inner bearing and seal. Drive inner bearing and seal out of hub with brass drift. Avoid damage to bearing cage.
3. Clean and inspect bearings and races. If bearings need replacement, drive outer races from hub with brass drift.

Scheme 14

1. If bearings are replaced, press new outer races into hub with Bearing Race Replacer (T75T 1225 A and T75T 1225 B). Ensure bearing race is seated correctly. Ensure a feeler gauge.0015" (.038 mm) thick does NOT fit between shoulder in hub and bearing race.
2. Pack bearings with multipurpose, lithium base grease. Place inner bearing in hub and install new inner seal with bearing race replacer. Tape over threads on end of spindle. Slide hub assembly over spindle, using care to avoid damaging seal lips.
3. Remove tape and install outer bearing with thrust washer and adjusting nut. Tighten adjusting nut to 120-140 ft. lbs. (163-190 N.m) while rotating wheel. Use Hex Lock Nut Wrench (T70T 4252 D) or Octal Lock Nut Wrench (T70T 4252 E) to tighten adjusting nut.
4. Back off adjusting nut until hub bearing end play is.001-.010" (.03-.25 mm). This should require 1/8 to 3/8 turn of adjusting nut. If end play is correct, place locking wedge into keyway in spindle and pound wedge into nylon retainer ring. (Scheme 14) NOTE: Locking wedge MUST cut new groove in nylon retainer. Nut and wedge must be replaced if nut cannot be positioned within correct end play range so that NEW groove is cut in nylon retainer.
5. Install axle shaft with new flange gasket, lock washers and new axle shaft retaining bolts. Tighten bolts to 40-50 ft. lbs. (54-68 N.m). Adjust brakes if necessary. (Scheme 14): Hub & Bearing Adjuster NOTE: Wedge MUST cut new groove in nylon retainer.

Installation & Adjustment (F350 Model)

1. If removed, position a new caged needle bearing in the spindle bore. Writing on bearing must face rear of spindle. Drive bearing in spindle with Spindle Bearing Replacer (T80T 4000 R) and Driver Handle (T80T 4000 W).
2. Pack bearing with Multi-Purpose Long Life Lubricant (C1AZ 19590 B). Install seal in bore against shoulder. Pack thrust face of seal in spindle bore and "V" seal on axle shaft with Multi-Purpose Long Life Lubricant (C1AZ 19590 B).
3. Carefully guide axle shaft through knuckle and into axle housing. Ensure axle shaft splines are engaged in differential side gear splines. Install bronze spacer on axle shaft assembly. Chamfered side of spacer must be inboard against axle shaft.
4. Install splash shield and caliper support bracket on steering knuckle. Place spindle on steering knuckle. Install nuts and tighten. Install hub and rotor assembly on spindle.
5. Install inner lock nut on spindle and seat bearing by tightening lock nut to 50 ft. lbs. (68 N.m) with Spanner Lock Nut Wrench (D85T 1197 A). Back off inner lock nut and retighten to 31-39 ft. lbs. (41-54 N.m).
6. While rotating hub and rotor, back off lock nut 135-150 degrees. Install lock washer so key is positioned in spindle groove. Rotate inner lock nut so pin is is aligned into nearest hole in lock washer.
7. Install outer lock nut and tighten to 160-205 ft. lbs. (217-278 N.m) using Spanner Lock Nut Wrench (D85T 1197 A). Final spindle end play should be no more than .006" (.15 mm). Install manual locking hub body assembly in hub and rotor.
8. Install lock ring in hub groove to retain body in hub. Install snap ring on end of axle shaft to retain shaft to body. Position cap assembly on body. Install 6 Allen-head capscrews and tighten to 35-45 INCH lbs. (4-6 N.m). To complete installation, reverse removal procedure.

FRONT AXLE SHAFTS

Note. After installing axle shafts, front hub bearings must be adjusted correctly. See HUB & BEARINGS for adjustment procedure.

Removal (F350)

1. Raise front axle of vehicle and install safety stands. Remove front wheel assembly. Remove brake caliper and wire to frame.
2. Remove 6 Allen bolts retaining cap to hub body and remove cap. Remove snap ring that retains axle shaft in hub body assembly. Remove lock ring seated in groove of wheel hub.
3. Remove body assembly from hub. If body is difficult to remove, install 2 capscrews and pull body assembly out of hub. Remove outer lock nut from spindle with Spanner Lock Nut Wrench (D885T 1197 A).
4. Remove hub and rotor assembly from spindle. Remove nuts retaining spindle to knuckle. Lightly tap spindle with a rawhide hammer to remove it from knuckle.
5. Pull axle shaft assembly out of steering knuckle. If required, remove bronze spacer from axle shaft assembly.
6. If required, remove caged needle bearing from spindle. Remove seal. Pull bearing out of spindle using 1 1/2-1 3/4" Collet (DD80L 100 U), Actuator Pin (D80L 100 H) and Bridge Assembly (D80L 100 W).

1. If removed, position a new caged needle bearing in spindle bore. Lettering on bearing must face rear of spindle. Drive bearing in spindle with Spindle Bearing Replacer (T80T 4000 R) and Driver Handle (T80T 4000 W).
2. Pack bearing with Multipurpose Long Life Lubricant (ESA M1C75 B). Carefully guide axle shaft through knuckle and into axle housing. Ensure axle shaft splines are engaged in differential gear splines.
3. Install bronze spacer on axle shaft assembly. The chamfered side of spacer must be inboard against axle shaft. Install splash shield and caliper support bracket on steering knuckle.
4. Place spindle on steering knuckle. Install nut and tighten. Install hub and rotor assembly on spindle. Install inner lock nut on spindle and seat bearing by tightening lock nut to 50 ft. lbs. (68 N.m) with Spanner Lock Nut Wrench (D86T 1197 A).
5. Back off inner lock nut and retighten to 31-39 ft. lbs. (31-39 N.m). While rotating hub and rotor, back off lock nut 135-150 degrees. Install lock washer so key is positioned in spindle groove. Rotate inner lock nut so pin is aligned into nearest hole in lock washer.
6. Using Spanner Lock Nut Wrench (D85T 1197 A), install outer lock nut and tighten to 160-205 ft. lbs. (217-278 N.m). Final spindle end play should be no more than .006" (.15 mm).
7. Install manual locking hub body assembly in hub and rotor. Install lock ring in hub groove to retain body in hub. Install snap ring on end of axle shaft to retain shaft to body.
8. Position cap assembly on body. Install 6 Allen capscrews and tighten to 35-45 INCH lbs. (4-6 N.m). To complete installation, reverse removal procedure.

Remove flange nuts from hub studs. Using hammer, rap sharply on center of axle flange to loosen tapered dowels. Remove dowels. Rap center of flange again to cause flange and axle assembly to spring away from hub. Remove axle without using prying devices which might damage axle flange and hub mating surfaces.

Clean mating surface of hub and axle flange. Install new gasket on face of hub. Insert axle shaft in housing and slide in until shaft splines engage with differential side gears. Tighten bolts holding axle shaft flange to hub.

PINION FLANGE & SEAL

Note. Front and rear differentials are same, except for oil slinger on front differential pinion shaft. Pinion seal can be serviced with axle assembly installed in vehicle.

1. Raise vehicle and support securely. Disconnect drive shaft at drive axle end and tie to side rail of frame. Mount Flange Holder Wrench (C-3281). Discard nut.
2. Remove flange using Flange Puller (C-452). Remove oil seal from carrier bore using Pinion Seal Puller (C-748). Use care to avoid damage to machine surfaces. Clean seal contact area thoroughly.

1. Lubricate cavity between seal lips with lithium base high pressure lubricant. Place seal in bore. Drive seal into carrier with Seal Installer (W-147-D on Model 44; C-3719-A with C-4735 on Model 60; C-359 on Model 70).
2. Place flange on end of pinion shaft. Press flange on pinion shaft, using flange holder and Flange Installer (C-496 on Model 44; C-3718 on Models 60 and 70). Leave flange holder in place and install pinion nut with washer. Tighten pinion nut to 200-220 ft. lbs. (271-298 N.m) on Models 44 and 70. On Model 60, tighten pinion nut to 240-300 ft. lbs. (325-407 N.m). CAUTION: Failure to tighten pinion nut to specification will result in flange or pinion shaft failure.

1. Raise vehicle on hoist and support axle assembly to take weight off springs. Disconnect drive shaft at pinion flange and tie out of way. Remove hub and brake assemblies.
2. Disconnect vent tube (if equipped). Disconnect parking brake cable(s) and service brake hydraulic lines. Disconnect shock absorbers at axle brackets. Disconnect springs and remove axle.

Reverse removal procedure. DO NOT fully tighten shock absorber nut until vehicle weight is on suspension. Bleed hydraulic lines and adjust parking brake before moving vehicle.

Scheme 15

1. Drain lubricant. Remove axle shafts and housing cover. If no side play is found in the differential case assembly, mount dial indicator on pilot stud with tip against back of ring gear. Measure runout of ring gear, marking ring gear and case at point of maximum runout.
2. If runout total exceeds.006" (.15 mm), ring gear could be loose or case could be damaged. Using.003" (.08 mm) feeler gauge, try to force feeler gauge between cap and race. If it does, bearing race may have been turning in carrier.
3. If race has been turning, carrier could be damaged. Observe identifying letters stamped into bearing caps and face of carrier sealing surface. Use these matched letters for reassembly reference.
4. Remove side bearing caps. Use Housing Spreader (W-129-A on Model 44; D-167 on Models 60 and 70) to spread differential housing to.015" (.38 mm). (Scheme 15) CAUTION: DO NOT spread housing more than.020" (.51 mm). Permanent damage to housing could result. (Scheme 15): Correct Procedure for Spreading Housing NOTE: DO NOT leave tension on carrier housing or damage will result.
5. Pry differential case out of housing. Remove spreader to prevent carrier taking set. On models with side bearing shims between carrier and side bearing outer race, record sizes and positions of shims. Be careful not to damage machined surfaces of housing.
6. Put case in soft-jawed vise and remove ring gear bolts and discard. Tap ring gear loose with soft mallet. If ring gear runout measured earlier exceeded.006" (.15 mm), repeat runout measurement of case without ring gear. Total runout of case should not exceed.003" (.08 mm).
7. Using Flange Holder Wrench (C-3281), remove drive pinion nut and washer. Using holder wrench and Flange Puller (C-452), remove drive pinion flange. Using Pinion Seal Puller (C0748), remove pinion oil seal. Remove slinger, gasket, outer pinion bearing and preload shim pack.
8. Remove drive pinion with inner bearing. Remove inner and outer pinion bearing races. Remove and note thickness of shim pack behind inner bearing race. Remove inner pinion bearing from pinion shaft using Puller Press (DD-914-P) with Adapter Ring (DD-914-9) and Pinion Bearing Puller Plates (C-293-39 on Model 44; DD-914-37 on Model 60; DD-914-95 on Model 70). NOTE: Pinion bearing adjusting shims may remain on pinion shaft, stick to bearing or fall loose. Collect and save them for reassembly.
9. Remove side bearings with Bearing Puller (C-293-PA), Extension Plug (C-293-3 on Model 44; DD-914-7 on Models 60 and 70) and Puller Plates (C-293-18 on Model 44; DD-914-62 on Models 60 and 70). Record shim thickness and location for reassembly reference.
10. If differential case is a one-piece unit, drive out lock pin holding differential pinion shaft to case. Remove differential pinion shaft, gears and thrust washers (one for each gear).
11. If differential case is a 2-piece unit, mark both differential case halves to aid reassembly in correct position. Remove bolts holding case halves together. Tap on top half of case to break it loose from lower half. Remove top half of case. Remove pinion gear spider, pinion gears, side gears and all thrust washers.

INSPECTION

1. Use cleaning solvent to rinse gears and bearings. Check large end of bearing rollers where wear, if any, is evident. Check pinion and flange splines for excessive wear. Ensure ring gear teeth are in good condition.
2. Check differential case for cracks, scoring of side gears, thrust washers and pinion thrust faces. Check fit of side gears to case and to axle shaft splines. Look at pinion shaft and spacer for scoring or excessive wear.

Scheme 16

1. When reassembling and adjusting ring and pinion assembly, pinion depth, pinion bearing preload, side bearing preload and backlash between ring and pinion must be adjusted.
2. If only pinion shaft and ring gear are to be replaced and carrier housing can be reused, compare pinion depth adjustment numbers etched in faces of the old and new pinion heads. (Scheme 16) Using «PINION VARIANCE CHART»(/ford/bronco-ii/i-1984-1990/remont/differentials-drive-axles/#drive-axle-full-floating) chart, correct shims can be selected for new pinion shaft depth adjustment. (Scheme 16): Pinion Gear Markings Showing Depth Adjustment Figures NOTE: Gear mating numbers on new ring and pinion gears must match. NOTE: In order to use «PINION VARIANCE CHART»(/ford/bronco-ii/i-1984-1990/remont/differentials-drive-axles/#drive-axle-full-floating) chart procedure, old pinion shaft shim pack dimensions MUST be determined accurately. If original pinion shaft shim pack dimension cannot be determined accurately, Pinion Depth Gauge Set (D-271) must be used to properly determine pinion depth setting. Depth gauge set must also be used if new carrier housing is to be used. PINION VARIANCE CHART Old Pinion Marking New Pinion Marking +4 -4 +0.008 -3 +0.007 -2 +0.006 -1 +0.005 0 +0.004 +1 +0.003 +2 +0.002 +3 +0.001 +4 0 +3 -4 +0.007 -3 +0.006 -2 +0.005 -1 +0.004 0 +0.003 +1 +0.002 +2 +0.001 +3 0 +4 -0.001 +2 -4 +0.006 -3 +0.005 -2 +0.004 -1 +0.003 0 +0.002 +1 +0.001 +2 0 +3 -0.001 +4 -0.002 +1 -4 +0.005 -3 +0.004 -2 +0.003 -1 +0.002 0 +0.001 +1 0 +2 -0.001 +3 -0.002 +4 -0.003 0 -4 +0.004 -3 +0.003 -2 +0.002 -1 +0.001 0 0 +1 -0.001 +2 -0.002 +3 -0.003 +4 -0.004 -1 -4 +0.003 -3 +0.002 -2 +0.001 -1 0 0 -0.001 +1 -0.002 +2 -0.003 +3 -0.004 +4 -0.005 -2 -4 +0.002 -3 +0.001 -2 0 -1 -0.001 0 -0.002 +1 -0.003 +2 -0.004 +3 -0.005 +4 -0.006 -3 -4 +0.001 -3 0 -2 -0.001 -1 -0.002 0 -0.003 +1 -0.004 +2 -0.005 +3 -0.006 +4 -0.007 -4 -4 0 -3 -0.001 -2 -0.002 -1 -0.003 0 -0.004 +1 -0.005 +2 -0.006 +3 -0.007 +4 -0.008

Scheme 17

1. Install side bearing caps, making sure reference marks made on caps and carrier match. Tighten cap bolts to 80-90 ft. lbs. (108-122 N.m). Check backlash between ring and pinion gears at 3 points spaced equal distance on ring gear. (Scheme 17) (Scheme 17): Measuring Backlash Between Ring & Pinion Gears NOTE: Maximum allowable variation of backlash is.002" (.05 mm).
2. Backlash reading between ring and pinion gears should be.004-.009" (.10-.23 mm). Maximum variation between readings at 3 points is.002" (.05 mm). If backlash is too high, move ring gear closer to pinion gear. If backlash is too low, move ring gear away from pinion gear.
3. To change backlash readings, move shims from one side of differential case to other. When backlash adjustment is completed, check tooth contact pattern. See «GEAR TOOTH CONTACT PATTERNS»(/ford/bronco-ii/i-1984-1990/remont/drivelineaxles/#gear-tooth-contact-patterns-general-information) article. Pattern should be correct if assembly and adjustments have been done properly.
4. When differential is complete and correctly adjusted, install new cover gasket and cover. Tighten cover bolts to 30-40 ft. lbs. (41-54 N.m). Fill assembly with Hypoid lubricant. AXLE ASSEMBLY SPECIFICATIONS Application Specifications In. (mm) Ring Gear Backlash.005-.009 (.13-.23) Side Bearing Preload.015 (.38) Pinion Gear Depth (Nominal Dimension) Model 44 2.625 (66.68) Model 60 & 61 3.125 (79.38) Model 70 3.500 (88.90) INCH lbs. (N.m) Pinion Bearing Preload New Bearings 20-40 (2.3-4.5) Used Bearings 10-20 (1.1-2.3)

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• LOCKING HUBS - AUTOMATIC
• GEAR TOOTH CONTACT PATTERNS
• MODEL IDENTIFICATION BY RING GEAR SIZE
• PINION FLANGE & SEAL
• HUB & BEARINGS