Differentials: Removal & Installation Lincoln LS I

Installation

Note. Make sure to position the shim on the front mount before raising the axle housing into position.

To install, reverse the removal procedure. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS .

Scheme 7

Scheme 8

1. Remove the axle housing assembly from the vehicle. See «AXLE HOUSING»(ref-142042-S21739472622002071600000).
2. Remove the rear axle differential front upper insulator. (Scheme 11)
3. Using the Differential Bushings Remover/Installer (205-485), remove the front axle differential front lower insulator. (Scheme 12)

Scheme 9

Scheme 10

1. Insert the rear axle differential front lower insulator and make sure that the notches are aligned forward and aft. (Scheme 13)
2. Using the Differential Bushings Remover/Installer (205-485) and Bushing Replacer (204-091), install the rear axle differential front lower insulator. (Scheme 14)
3. Install the rear axle differential front upper insulator. (Scheme 11)
4. Install the rear axle housing. See «AXLE HOUSING»(ref-142042-S21739472622002071600000). Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-142042-S38260000202002071600000).

Removal

Scheme 11

Scheme 12

Scheme 13

1. Remove and secure the rear brake calipers aside. See «DISC -- LS»(ref-96470) article.
2. Disconnect and position the driveshaft out of the way. See «DRIVE SHAFTS & UNIVERSAL JOINTS -- CARS»(ref-97873) article.
3. Install a INCH pound torque wrench on the pinion nut. Record the torque necessary to maintain rotation of the drive pinion gear through several revolutions. (Scheme 15)
4. Install the Drive Pinion Flange Holding Tool. Install a suitable breaker bar and remove the nut.
5. Mark the pinion flange in relation to the drive pinion stem to ensure correct alignment during installation. (Scheme 17)
6. Using the Output Flange Remover (307-408), remove the pinion flange. (Scheme 18)

Scheme 14

1. Lubricate the pinion flange splines. Use SAE 75W140 Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.
2. Align the pinion flange with the drive pinion shaft. (Scheme 19)
3. Using the Drive Pinion Flange Installer (205-479) and Drive Pinion Flange Holding Tool (205-478), install the pinion flange. (Scheme 20)
4. Use the Drive Pinion Flange Holding Tool (205-478) to hold the pinion flange while tightening the 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. Se (Scheme 15).
5. If the preload recorded prior to disassembly is lower than the specification for used bearings, then tighten the pinion nut to specification. See «PINION BEARING PRELOAD SPECIFICATIONS»(ref-142042-S27688492042002111100000) under GENERAL SPECIFICATIONS. If the preload recorded prior to disassembly is higher than the specification for used bearings, then tighten the pinion nut to the original reading as recorded. See «PINION BEARING PRELOAD SPECIFICATIONS»(ref-142042-S27688492042002111100000) under GENERAL SPECIFICATIONS.
6. Connect the driveshaft. See «DRIVE SHAFTS & UNIVERSAL JOINTS -- CARS»(ref-97873) article.
7. Install the rear brake calipers. See «DISC -- LS»(ref-96470) article.
8. Install the rear wheel and tire assemblies. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-142042-S38260000202002071600000).

1. Remove the pinion flange. See «DRIVE PINION FLANGE»(ref-142042-S25979515442002071700000).
2. Force up the metal flange of the rear axle drive pinion seal. (Scheme 21)
3. Strike the pliers with a hammer to remove the rear axle drive pinion seal. (Scheme 22)

1. Lubricate the lips of the new rear axle drive pinion seal. Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification (ESA-M1C75-B).
2. Using Pinion Seal Replacer (205-133), install the rear axle drive pinion seal. (Scheme 23)

Scheme 15

Scheme 16

Scheme 17

1. Remove the axle shaft assembly. See «AXLE SHAFTS - REAR, LS»(ref-142043) article.
2. Install the Bearing Cup Remover (308-047) and Slide Hammer (100-001) with the tangs firmly engaged on the inboard CV joint stub shaft pilot bearing housing. (Scheme 24) Remove the inboard CV joint stub shaft pilot bearing housing seal and inboard CV joint stub shaft pilot bearing.

Scheme 18

Scheme 19

Scheme 20

1. Lubricate the new inboard CV joint stub shaft pilot bearing with SAE 75W140 Synthetic Rear Axle Lubricant F1TZ-19580-B, or equivalent meeting Ford specification (WSL-M2C192-A). Place the inboard CV joint stub shaft pilot bearing onto the Needle Bearing Replacer (205-288) and Handle (205-153). (Scheme 25)
2. Install the inboard CV joint stub shaft pilot bearing into the rear axle housing bore. (Scheme 26)
3. Lubricate the lip of the inboard CV joint stub shaft pilot bearing housing seal with Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification (ESA-M1C75-B). Place the inboard CV joint stub shaft pilot bearing housing seal onto the Differential Seal Replacer (205-293) and Handle (205-153). (Scheme 27)
4. Carefully align the inboard CV joint stub shaft pilot bearing housing seal with the housing bore and install the inboard CV joint stub shaft pilot bearing housing seal. (Scheme 26)
5. Install the axle shaft. See «AXLE SHAFTS - REAR, LS»(ref-142043) article.

Scheme 21

Scheme 22

Scheme 23

Scheme 24

Scheme 25

Scheme 26

Scheme 27

Scheme 28

Scheme 29

Scheme 30

Scheme 31

Scheme 32

Scheme 33

Scheme 34

Scheme 35

Scheme 36

Scheme 37

1. Remove the differential housing cover.
2. Mount the rear axle housing on the Transmission Holding Fixture (307-003). Attach the Differential Housing Plate (205-335) to the rear axle housing with four cover bolts. Attach the Differential Housing Plates Spreader to the Transmission Holding Fixture with two 3/8" x 1-1/2" bolts. (Scheme 28)
3. Install the Differential Carrier Spreader (205-001), onto the Differential Housing Plates Spreader Adapters with the spreader pins aligned with the holes in the Housing Spreader Adapters. (Scheme 29)
4. Install the Dial Indicator Gauge (100-D005), or equivalent. Attach the Clutch Housing Aligning Adapter (308-021) to the Dial Indicator Gauge with the tip positioned in the spreader adapter hole. (Scheme 30)
5. Adjust the dial indicator to zero and tighten the housing spreader screw until the rear axle housing is spread to 0.030" (0.762 mm). Remove the dial indicator. (Scheme 31)
6. Remove the differential bearing caps. Remove the bearing cap retaining bolts. Remove the differential bearing caps. (Scheme 32)
7. Position wood blocks on top and bottom of the differential. Pry the differential case and the differential bearing shims out of the rear axle housing. Remove the Differential Carrier Spreader (205-001), or equivalent. (Scheme 33)
8. Remove the 10 ring gear bolts. (Scheme 34)
9. Insert a punch in the bolt holes and drive the ring gear off. (Scheme 35)
10. Using the 2-Jaw Puller (205-D072) and Step Plate (205-D061), or equivalent, remove the differential bearing. Repeat for the other side. (Scheme 36)
11. Remove the differential pinion shaft lock bolt. (Scheme 37)
12. Remove the differential pinion shaft. see scheme 38
13. Remove the differential gears. see scheme 39
14. Remove the differential side gears. see scheme 40
15. Install an INCH pound torque wrench on the pinion nut. Record the torque necessary to maintain rotation of the drive pinion gear through several revolutions. (Scheme 15)
16. Mark the pinion flange in relation to the drive pinion stem to ensure correct alignment during installation. (Scheme 17)
17. Remove the pinion nut. Install the Drive Pinion Flange Holding Tool (205-478). Install a suitable breaker bar and remove the nut.
18. Using the Output Flange Remover (307-408), remove the pinion flange. see scheme 41
19. 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. see scheme 42 Remove the rear axle drive pinion shaft oil slinger, the rear axle drive pinion seal and the collapsible spacer.
20. Remove the front pinion bearing. Position the Bearing Remover (205-055) under the pinion bearing. Using a press, remove the pinion bearing. see scheme 43
21. Remove the drive pinion bearing adjustment shim. see scheme 44
22. If required, remove damaged rear axle pinion bearing cup from the rear axle housing using the Drive Pinion Outer Bearing Cup Remover (205-482) and Adapter. see scheme 45
23. If required, remove rear axle pinion bearing cup from the rear axle housing using the Drive Pinion Inner Bearing Cup Remover (205-481) and Handle (205-153). see scheme 46