Differentials: Overhaul — Lincoln LS I (1999-2002)

Reassembly (Aluminum)

CAUTION

Lubricate the differential side gear thrust washers with Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B prior to installation.

Scheme 38

Scheme 39

Scheme 40

Scheme 41

Scheme 42

Scheme 43

Scheme 44

Scheme 45

Scheme 46

Scheme 47

Scheme 48

Scheme 49

Scheme 50

Scheme 51

Scheme 52

Scheme 53

Scheme 54

Scheme 55

Scheme 56

Scheme 57

Scheme 58

Scheme 59

Scheme 60

Scheme 61

Scheme 62

Install the differential side gears in the differential case. (Scheme 40)
Install the differential pinion gears with the differential pinion thrust washers in the differential case. (Scheme 39)
Install the differential pinion shaft. Install a new differential pinion shaft lock bolt. see scheme 37
Use the Differential Side Bearing Installer (205-010) to install the differential bearing on the differential case. Repeat for the other side. (Scheme 47)
Install the differential case without the ring gear. (Scheme 48) Rotate the differential case to correctly seat the differential bearings.
Check the differential case flange runout using the Dial Indicator Gauge with Holding Fixture (100-002) or equivalent (Scheme 49) If the runout is within specification, install a new ring gear and pinion. If the runout exceeds specification, the ring gear is true and the concern is due to either a damaged differential case or differential bearings. Inspect the differential bearings. If the differential bearings are not damaged, install a new differential case and the differential bearings. Recheck the runout with the new differential case and differential bearings.
Remove the differential case.
Press the ring gear on the differential case. (Scheme 50) Start two of the ring gear bolts through the differential case and into the ring gear to make sure the ring gear bolt holes align with the differential case bolt holes correctly.
Install the ring gear bolts. (Scheme 51) Apply Stud and Bearing Mount (E0AZ-19554-BA), or equivalent meeting Ford specification (WSK-M2G349-A1) to the ring gear bolts. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-142042-S38260000202002071600000).
With the pinion removed, place the differential case/gear subassembly with the differential bearing and the rear axle pinion bearing cups in the rear axle housing. (Scheme 52)
Install a differential bearing shim of the thickness shown on the left side of the differential case. (Scheme 53)
Install the left bearing cap finger-tight. (Scheme 54)
Install progressively larger differential bearing shims on the right side until the largest differential bearing shim selected can be assembled with a slight drag feel. (Scheme 55)
Install the right bearing cap. (Scheme 56) Tighten both bearing caps to specification. See «TORQUE SPECIFICATIONS»(ref-142042-S38260000202002071600000).
Rotate the differential assembly to make sure it rotates freely. (Scheme 57)
Remove the differential assembly from the axle housing.
Install a new inner rear axle pinion bearing cup in the rear axle housing. (Scheme 58)
Install a new outer rear axle pinion bearing cup in the rear axle housing. (Scheme 59)
Position the rear axle pinion bearing cup on the Drive Pinion Bearing Cup Installer (205-054). Position the bearing cup replacer in the rear axle housing. (Scheme 60) Tighten the Drive Pinion Bearing Cup Installer (205-054) to fully seat the rear axle pinion bearing cup in the bore.
Install the special tools. (Scheme 61)
Thread the Adapter (205-111) onto the screw and tighten to 20 INCH lbs. (2.2 N.m). (Scheme 62) See «TORQUE SPECIFICATIONS»(ref-142042-S38260000202002071600000).
Rotate the Adapter (205-110) several half turns to correctly seat the pinion bearings.
Install the Drive Pinion Gauge Tube (205-336). Position the drive pinion gauge tube on the differential bearing seat of the rear axle housing. (Scheme 64) Install the differential bearing caps. Install the differential bearing cap bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-142042-S38260000202002071600000).
Select and check the correct shim size. see scheme 65
Remove the Drive Pinion Gauge Tube (205-336).
Position the drive pinion bearing adjustment shim on the pinion stem. see scheme 66 Position the pinion bearing on the pinion stem. Position the Bearing/Oil Seal Plate (205-090) on the pinion stem. Using a press, firmly seat the drive pinion bearing adjustment shim and pinion bearing on the pinion stem.
Install the front pinion bearing, the rear axle drive pinion shaft oil slinger and the rear axle drive pinion seal in the differential housing.
Place a new drive pinion collapsible spacer on the pinion stem against the pinion stem shoulder. see scheme 67
Install the drive pinion and the new drive pinion collapsible spacer into the rear axle housing. see scheme 68
Remove the differential bearings. Install the Differential Bearing Gauges (205-338) and (205-339) onto the differential case. see scheme 69
Install the rear axle pinion flange. Align the rear axle pinion flange with the drive pinion shaft. see scheme 19
With the drive pinion in place in the rear axle housing, install the rear axle pinion flange using the Drive Pinion Flange Holding Tool (205-478) and Drive Pinion Flange Installer (205-479). see scheme 20
Use Drive Pinion Flange Holding Tool (205-478) to hold the pinion flange while tightening the new pinion nut. Rotate the pinion occasionally to make sure the differential pinion bearings seat correctly. Take frequent differential pinion bearing torque preload readings by rotating the pinion with an INCH pound torque wrench. Refer to the torque specification for pinion bearings. See «PINION BEARING PRELOAD SPECIFICATIONS»(ref-142042-S27688492042002111100000).
Place the differential case and the Differential Bearing Gauges (205-338 and 205-339) into the rear axle housing. see scheme 70
Position the Dial Indicator Gauge With Holding Tool (100-002) on the outside mounting hole. see scheme 71
Attach the Dial Indicator Gauge (100-002) with the indicator tip positioned on the machined surface of the differential case flange. see scheme 72 Move the differential case to the left and the right (as far as possible). Record the reading on the differential bearing shim selection procedure line A. see scheme 73
Remove the dial indicator and the differential case from the rear axle housing. see scheme 74
Draw-file the differential ring gear mounting surface to remove any nicks or burrs. see scheme 75
Install the ring gear. see scheme 76 Place the ring gear onto the differential case. Hand start three bolts to align the holes in the ring gear and the differential case. Place the differential case and ring gear onto the press bed blocks with the ring gear teeth facing down. Press the ring gear into place.
Install the remaining ring gear bolts and tighten to specification. (Scheme 51) Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-142042-S38260000202002071600000).
Place the differential case, Differential Bearing Gauges (205-338 and 205-339), and the ring gear into the rear axle housing. see scheme 70
Attach the dial Indicator with the indicator tip positioned on the machined surface of the differential case flange. see scheme 77 Rock the ring gear to allow full mesh with the pinion gear. With the gears in full mesh, set the dial indicator to zero. Move the differential case as far as possible to the left and note the reading. Record the reading on the differential bearing shim selection procedure line B. see scheme 73
Remove the Dial Indicator and the differential case from the rear axle housing.
Install the Bearing Preload Gauge (205-S337). see scheme 78 Place the bearing preload gauge base in a soft-jawed vise with the bearing mounting surface above the vise jaws. Position the differential bearing assembly on the bearing preload tool base. Attach the bolt, spring, washers and spacer. Tighten the bolt to specification. see scheme 78
Measure the differential bearing stand height. Invert the Bearing Preload Gauge (205-S337) and clamp the bolt head in a vise. Position a depth micrometer flat on the differential bearing assembly. see scheme 79
Measure the stand height of both differential bearing assemblies and record on the differential bearing shim selection procedure line D. see scheme 73
Press the left and right differential bearing on the differential case. see scheme 80
Install the Differential Carrier Spreader (205-001) and Dial Indicator Gauge (100-002). see scheme 81
Adjust the Dial Indicator Gauge to zero and tighten the Differential Carrier Spreader screw to spread the rear axle housing to specification. see scheme 31 Remove the Dial Indicator Gauge.
Select the correct size differential bearing shims by using the differential bearing shim selection chart. see scheme 82 Install the differential bearing shims. see scheme 83 Place the differential bearing shims in the rear axle housing.
Position the differential bearing cups on the differential bearings. see scheme 84 Lower the differential case in place between the differential bearing shims.
Install the bearing caps in their original positions and tighten the bolts to specification. see scheme 85 See «TORQUE SPECIFICATIONS»(ref-142042-S38260000202002071600000).
Remove the Differential Carrier Spreader. Move the Dial Indicator Gauge (100-002) to the 12 o'clock position. see scheme 86
Attach the dial indicator. Position the indicator needle centrally on a drive tooth. see scheme 87 Zero the indicator. Turn the ring gear without turning the pinion gear. Record the indicator reading.
If the backlash is not to specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness of the other differential bearing shim by the same amount. see scheme 88
If the backlash is within specification, install the differential housing cover. Apply a new continuous bead of sealant to the differential housing cover. see scheme 89 Use Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specifications ESB-M4G92-A.
Install the rear axle. See «AXLE HOUSING»(ref-142042-S21739472622002071600000) under REMOVAL & INSTALLATION.
Refill the rear axle. Fill the rear axle 3-5 mm (1/8-3/16 inch) from the bottom of the filler hole with SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B, or equivalent meeting Ford specification WSL-M2C192-A.

Scheme 63

Scheme 63: Disassembly (Nodular Iron)

Remove the differential housing cover.
Mount the rear axle housing on the Transmission Holding Fixture 303-003 (T57L-500-B). see scheme 28 Attach the Differential Housing (Plate) Spreader to the rear axle housing with four cover bolts. Attach the Differential Housing (Plate) Spreader to the Transmission Holding Fixture with two 3/8 inch x 1-1/2 inch bolts.
Remove the differential bearing caps. see scheme 90
Remove the differential case. see scheme 91
Remove the 10 ring gear bolts. see scheme 34
Insert a punch in the bolt holes and drive the ring gear off. see scheme 35
Using the Step Plate (205-D061) and the 2-Jaw Puller (205-D072), remove the differential bearing. Repeat for the other side. see scheme 36
Remove the differential pinion shaft lock bolt. see scheme 37
Remove the differential pinion shaft. (Scheme 38)
Remove the differential gears. (Scheme 39)
Remove the differential side gears. (Scheme 40)
Install an INCH pound torque wrench on the pinion nut and record the torque necessary to maintain rotation of the drive pinion gear through several revolutions. see scheme 15
Mark the pinion flange in relation to the drive pinion stem to ensure correct alignment during installation. see scheme 17
Remove the pinion nut. Install the Drive Pinion Flange Holding Tool (205-478). Install a suitable breaker bar and remove the nut.
Using the Output Flange Remover (307-408), remove the pinion flange. (Scheme 41)
Install the Drive Pinion Thread Protector (205-460), and with a soft-faced hammer, drive the pinion out of the front bearing cone and remove it through the rear of the housing. (Scheme 42) Remove the rear axle drive pinion shaft oil slinger, the rear axle drive pinion seal and the collapsible spacer.
Remove the front pinion bearing. Position the Bearing Remover (205-055) under the pinion bearing. Using a press, remove the pinion bearing. (Scheme 43)
Remove the drive pinion bearing adjustment shim. (Scheme 44)
Remove damaged rear axle pinion bearing cup from the rear axle housing using the Drive Pinion Outer Bearing Cup Remover (205-482) and Handle (205-153). (Scheme 45)
Remove damaged rear axle pinion bearing cup from the rear axle housing using the Drive Pinion Inner Bearing Cup Remover (205-483) and handle. (Scheme 46)

Reassembly (Nodular Iron)