Differentials - Awd - Rear Ford Tempo I

IDENTIFICATION

The vehicle certification label is located on the left front door lock panel. The axle ratio is identified by the character located under the "AX" (axle). Use this character and table to determine the vehicle ratio. See AXLE RATIO IDENTIFICATION table.

AXLE RATIO IDENTIFICATION

DESCRIPTION & OPERATION

Rear axle assembly is an integral-type housing, hypoid gear design. The center line of the drive pinion is below the center line of the ring gear. The ring gear diameter is 4.75" (120.7 mm) and is bolted to differential assembly. The drive pinion is supported by 2 opposed bearing assemblies.

The differential assembly consists of a 1-piece case with 2 openings to allow for service and lubricant flow. The axles are splined into side gears and retained with snap rings. Differential is equipped with Traction-Lok consisting of disc and plate assemblies located on the axle side of each side gear.

Rear axle receives power from engine through transaxle transfer case and drive shaft. Drive shaft is a 2 piece with a unique center yoke phasing that MUST be maintained. With all-wheel drive disengaged, the rear wheels drive the axle shafts, rear differential, and driveshaft.

LUBRICATION

The rear axle assembly uses 20.5 ozs. (581 g) of Hypoid Gear Lubricant (C6AZ-1958-E) and 1.5 ozs. (43 g) of Friction Modifier (C8AZ-19B546-A).

REAR DIFFERENTIAL ASSEMBLY

Note. Remove rear axle assembly and place on work bench to perform all repairs.

Removal

1. Raise and support vehicle. Position a jack under axle assembly. Remove exhaust system from catalytic converter back. Index drive shaft-to-yoke flanges. Remove rear "U" joint bolts retaining drive shaft. Lower drive shaft. Remove torque tube support bracket mounting bolts. Remove damper and position drive shaft out of way. CAUTION: Any time a "U" joint retaining bolt is removed, Loctite 242 (Ford specification E0AZ-14554-A) must be applied to threads.
2. Remove left and center axle support mounting bolts. Index axle shaft-to-yoke mounting. Lower differential assembly enough to remove bolts retaining inner axle shafts. Remove both axle shafts from differential and support with wire. Lower and remove differential. CAUTION: Apply Loctite 242 (Ford specification E0AZ-14554-A) to all removed "U" joint bolts.

Installation

Position differential under vehicle and raise enough to connect axle shafts. Align marks made during removal and attach axle shafts. To complete installation, reverse removal procedure. Tighten all bolts/nuts to specifications. Fill differential with specified lubricant.

Removal & Installation

Remove rear suspension control arm bolt. Index inner and outer axle shaft-to-yoke. Remove "U" joint bolts. Slide axle shaft together and remove axle shaft. To install, reverse removal procedure. Tighten bolts/nuts to specification.

Scheme 1

Disassembly

1. Remove axle shaft to be repaired and place on work bench. See «AXLE SHAFTS»(/ford/tempo/i-1983-1994/remont/differentials-drive-axles/#differentials-awd-rear) under REMOVAL & INSTALLATION. Index axle shaft at splined joint before separating. Cut and remove boot clamps. Separate axle shaft.
2. Remove and discard "U" joint snap rings. Using "U" Joint Remover (T74P-4635-C), remove bearings from yoke.

Reassembly

1. Fill boot with approximately 10 grams of Multipurpose Long-Life Lubricant (C1AZ-19590-B). Coat splines with same lubricant. Install original equipment clamps and boot on shaft with external splines. Align index marks and carefully install axle shafts. Ensure splines are properly aligned. DO NOT force shafts together.
2. Remove excess grease and air pressure from boot and slip yoke. Install clamps on boot and retain with Clamp Pliers (T63P-9171-A). To complete installation, reverse disassembly procedure.

Scheme 2

1. Remove differential. See «REAR DIFFERENTIAL ASSEMBLY»(/ford/tempo/i-1983-1994/remont/differentials-drive-axles/#differentials-awd-rear) under REMOVAL & INSTALLATION. Place differential assembly on work bench. Remove protective shield from torque tube-to-differential. Remove bolts retaining torque tube to differential and remove torque tube.
2. Remove 2 mounting bolts retaining support bracket to torque tube. Pull input shaft from torque tube and place shaft horizontally in a vise with protected jaws. Remove adapter sleeve snap ring. Position shaft vertically in vise. Remove adapter sleeve.
3. Use a 2 jaw-type puller and remove splined coupling from shaft. Remove splined coupling "O" ring. Remove sleeve spring snap ring. Remove sleeve spring, flatwasher and adapter sleeve retaining ring. (Scheme 1)
4. Place yoke side of input shaft in vise. Remove snap ring retaining bearing-to-shaft. Use a press and remove bearing and bracket from shaft. Replace bracket if it is bent or damaged. Remove seal from torque tube with a 3 jaw-type puller and discard seal.
5. Remove differential housing cover bolts. Remove cover and drain lubricant. Remove both side gear snap rings and remove both inner yoke shafts. Use a 3 jaw-type puller and slide hammer to remove side bearings and seals from left and right yoke bore.
6. Remove 4 bearing retaining cap bolts from left side of differential. Remove bearing retaining cap and discard "O" ring. Remove differential case assembly from differential housing. Use a 2 jaw-type puller and remove side bearings. Mark bearings for reassembly.
7. Remove ring gear retaining bolts. Alternately tap ring gear off of case. Place differential case on short axle shaft and mount axle shaft yoke vise. Remove roll pin retaining pinion shaft to case. Remove pinion shaft out roll pin end.
8. Remove differential case from short axle shaft and place on bench with short axle shaft side down. Install Step Plate (D80L-630-1) between side gears. Install forcing screw through long yoke shaft bore. Place Threaded Adapter (T87P-4205-A) between step plate and side gear. (Scheme 2) Thread forcing screw into adapter.
9. Place differential case on short yoke shaft. Tighten forcing screw until pinion gears become loose. Use an appropriate feeler gauge and push pinion gear thrust washers from differential case. DO NOT mix thrust washers and pinion gears. Rotate differential case until pinion gears can be removed and remove pinion gears.
10. Remove differential case from short yoke shaft. Remove tooling. Remove one side gear at a time using care not to drop clutch pack. DO NOT mix components.
11. Remove and discard pinion adapter "O" ring at pinion. Remove staked portion on pinion nut and remove nut. Tap pinion with soft hammer and remove pinion. Retain preload spacer and shim(s) for reassembly. Remove outer pinion bearing. Press inner bearing from pinion and retain any shim(s).
12. Remove inner and outer pinion bearing races and side bearing races with 3 jaw-type puller and slide hammer. Remove left and center support bushing from axle housing (if replacing), with a "C" clamp and appropriate adapter.

Inspection

1. Thoroughly clean components with clean solvent (except clutch pack). Inspect all bearings and races for pitting, scoring and damage. Inspect ring gear and drive pinion for tooth contact pattern, cracks or damage. Replace ring and pinion as a set only.
2. Check differential case for cracks and damage. Ensure pinion gear thrust washer surface of case is not damaged. Inspect pinion gears, side gears and pinion gear shaft for wear or damage. Inspect clutch pack for wear or burnt surfaces.
3. Inspect axle housing for cracks and damage. Check for metal or contamination in bottom of axle housing. Inspect axle shaft for wear and damage. Check boots for cracks or splits. Replace defective components as necessary.

Scheme 3

Scheme 4

Scheme 5

Scheme 6

Scheme 7

1. Lubricate clutch pack with Friction Modifier Additive (C8AZ-19B546-A). Reassemble left side gear and clutch pack. With short shaft of differential case facing up, install left side gear assembly with retainers aligned with differential case.
2. Hold left hand side gear in place and turn differential case over. Reassemble and install right side gear as stated in step 1). Ensure retainers are aligned with differential case. Install tooling used at disassembly. (Scheme 2) Place differential case on short yoke shaft and tighten, forcing-screw slightly.
3. Place differential pinion gears and thrust washers in position in opening of case. Ensure gears are 180 degrees apart with shaft bore of gears aligned. Ensure pinion gears are in proper mesh with side gears. Rotate differential case until pinion gears are aligned with shaft bore.
4. With differential pinion gears installed, remove tooling. Install pinion shaft and roll pin. DO NOT install ring gear at this time. Set differential case aside.
5. Install the inner and outer pinion bearing race in the differential housing, with an appropriate size driver. Install Handle (T76P-4020-A11), Screw (T80T-4020-F43), Dummy Pinion Aligning Adapter (T76P-4020-A14) and Gauge Block and Disc Kit (T87P-4020-A) into inner pinion bearing bore. Slide Gauge Bar (T87P-4020-A1) through left side of case. (Scheme 3)
6. Install bearing retaining cap with "O" ring from block and disc kit. Tighten retaining cap screws snug. Use a feeler gauge or shim and determine distance between gauge bar and block. A slight drag should be felt. Check pinion gear for an etched reading.
7. If pinion gear is marked with a (+) amount, this amount must be subtracted from obtained feeler gauge or shim thickness amount found in step 6). If pinion gear is marked with a (-) amount, this must be added to amount found in step 6). Add or subtract for proper shim to be used.
8. Press inner pinion bearing and proper shim on pinion. Install disassembled preload spacer, shim(s) and new "O" ring on pinion. Place pinion assembly in differential housing. Install outer pinion bearing race. Install and tighten pinion nut, but DO NOT stake at this time.
9. Use an INCH lb. torque wrench and measure pinion rotation torque. Rotation torque should be 15-35 INCH lb. (1.7-4 N.m). If not within specifications, add or remove shims as necessary. Install Gauge Bar (PS85-167-1-1A) and Dummy Pinion (PS85-167-1-3). (Scheme 4) Use a feeler gauge or shim and measure clearance. A slight drag should be felt.
10. Drive pinions are machined and fitted at factory. An etched value is located on the drive pinion gear in either a plus (+) or a minus (-). Note the etched value and use for setting drive pinion height.
11. If drive pinion is not etched with a value the pinion is zero. The standard pinion height is.020" (.051 mm) with a tolerance of plus (+) or minus (-).002" (.051 mm). Use the example in step 12) for etched value specifications.
12. For example, a drive pinion with etched value of -2 would have an.18" (.46 mm) distance with a tolerance of.002" (.051 mm). The shim requirement amount would be.016-.020" (.40-.50 mm).
13. To adjust the distance, remove or increase shim (s) located beneath inner pinion bearing cone. Use thinner shim(s) to increase or thicker shim(s) to decrease the distance. With pinion set to specifications, recheck rotation torque. With rotation torque at specifications, stake pinion nut.
14. Install Master Bearings (T87P-4222-A) on differential case. (Scheme 5) Place differential housing in a vise with bearing retainer cap upward. Install differential case in housing. Install bearing retainer cap. Mount a dial indicator to bearing retainer cap. Tighten bearing retainer cap to 20-26 ft. lbs. (27-35 N.m).
15. Adjust dial indicator so tip touches machined end of differential case trunnion. Zero dial indicator. (Scheme 6) Lift differential case upward and record reading on dial indicator. Repeat procedure and use the consistent reading for shim selection.
16. Remove dial indicator and differential case from housing. Install ring gear and tighten to specifications. Reinstall differential case in housing with master bearings still installed on case. Reinstall bearing retainer cap and dial indicator as in step 14) and 15). (Scheme 6)
17. Lift differential case upward and record reading. Repeat procedure and use the consistent reading for shim selection. Using the consistent reading, subtract reading with ring gear installed from reading without ring gear installed. Use this total for shim thickness on pinion side of case. NOTE: Pinion side of case is the tooth side of mounted ring gear. Ring gear side of case is the backside of mounted ring gear.
18. For ring gear side of case, use the consistent reading and subtract reading with ring gear from reading without ring gear. Subtract and additional.008" (.20 mm) from the total. Use this total for shim thickness on ring gear side.
19. Remove differential case. Remove master bearings. Install proper selected shim(s) to proper side and install side bearings with an appropriate size driver. Install side bearing race in bearing retainer cap with appropriate size driver. Thoroughly lubricate bearings and races.
20. Install differential case assembly in housing. Install and tighten bearing retainer cap. Mount a dial indicator and measure ring gear backlash in 3 equally spaced points. (Scheme 7) Backlash should be.004-.006" (.10-.15 mm). If backlash is excessive, change side bearing shim(s) from pinion side to ring gear side. This will move ring gear closer to pinion.
21. If backlash is less than specifications, change shim(s) from ring gear side to pinion side. This will move ring gear away from pinion. With backlash within specifications, check total pinion rotating torque. Pinion rotating torque with case assembly installed should be 4-7 INCH lb. (50-80 N.m).
22. With backlash and pinion rotating torque within specification, complete reassembly by reversing disassembly procedure. Install axle shaft bearings in differential housing with name on bearing facing axle shaft (outboard side). Ensure to align all matching marks made at disassembly. Tighten all bolts/nuts to specifications. Fill differential assembly with specified grease.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATION

See also:
• AXLE RATIO IDENTIFICATION