40697115 ws manual 1999 f super duty s 1 g 00 gen info amp s2 susp driveline part 1 a

Workshop Manual

1999

F-Super Duty 250-550

1999 F-Super Duty 250-550

Workshop Manual

Alphabetical Index

A B C D E F

G H I J K L

M N O P R S

T U V W

Specifications Table of Contents

1: General Information

00: Service Information

2: Chassis

04: Suspension

05: Driveline

06: Brake System

11: Steering System

3: Powertrain

03: Engine

07: Automatic Transmission

08: Manual Transmission, Clutch and Transfer Case

09: Exhaust System

10: Fuel System

4: Electrical

12: Climate Control System

13: Instrumentation and Warning Systems

14: Battery and Charging System

15: Audio Systems

17: Lighting

18: Electrical Distribution

19: Electronic Feature Group

5: Body and Paint

01: Body

02: Frame and Mounting

GROUP 00: Service Information

SECTION 100-01: Identification Codes

SECTION 100-02: Jacking and Lifting

SECTION 100-04: Noise, Vibration and Harshness

SECTION 100-01:

Identification Codes

DESCRIPTION AND OPERATION


SECTION 100-01: Identification Codes 1999 F-Super Duty 250-550 Workshop Manual

DESCRIPTION AND OPERATION Procedure revision date: 01/26/2000


The vehicle identification number (VIN) is a 17-digit combination of letters and numbers. The VIN is stamped on a metal tab riveted on the instrument panel top upper left of the dash. The VIN number is also found on the vehicle certification (VC) label.

Item Description

1 World Manufacturer Identifier

2 Brake Type and Gross Vehicle Weight Rating (GVWR)

3 Vehicle Line, Series, Body Type

4 Engine Type

5 Check Digit

6 Model Year

7 Assembly Plant

8 Production Sequence Number

Vehicle Identification Number

The first three vehicle identification number (VIN) positions are the world manufacturer code.

• 1FT — Ford Motor Company, USA, truck, completed vehicle • 1FD — Ford Motor Company, USA, incomplete vehicle • 1FC — Ford Motor Company, USA, basic (stripped) chassis • 1FF — Ford Motor Company, USA, motor vehicle equipment without engine/powertrain

(Glider) • 3FC — Ford Motor Company, Mexico, basic (stripped) chassis • 3FE — Ford Motor Company, Mexico, incomplete vehicle • 3FT — Ford Motor Company, Mexico, truck, completed vehicle

The fourth VIN position is the vehicle brake type and GVW code (all vehicles use hydraulic brakes).

• H — 8,501-9,000 pounds GVWR • J — 9,001-10,000 pounds GVWR • K — 10,001-14,000 pounds GVWR • L — 14,001-16,000 pounds GVWR • M — 16,001-19,501 pounds GVWR • N — 19,501-26,000 pounds GVWR • N — 8,501-9,000 pounds GVWR with second generation air bags • S — 9,001-10,000 pounds GVWR with second generation air bags • W — 10,001-14,000 pounds GVWR with second generation air bags • X — 14,001-16,000 pounds GVWR with second generation air bags • A — 16,001-19,500 pounds GVWR with second generation air bags

Positions 5 through 7 indicate vehicle line, series and body type.

• F20 — F-250 Regular Cab, 4x2 (single rear wheels) • F21 — F-250 Regular Cab, 4x4 (single rear wheels) • X20 — F-250 SuperCab, 4x2 (single rear wheels) • X21 — F-250 SuperCab, 4x4 (single rear wheels) • W20 — F-250 Crew Cab, 4x2 (single rear wheels) • W21 — F-250 Crew Cab, 4x4 (single rear wheels) • F30 — F-350 Regular Cab, 4x2 (single rear wheels) • F31 — F-350 Regular Cab, 4x4 (single rear wheels) • X30 — F-350 SuperCab, 4x2 (single rear wheels) • X31 — F-350 SuperCab, 4x4 (single rear wheels) • W30 — F-350 Crew Cab, 4x2 (single rear wheels) • W31 — F-350 Crew Cab, 4x4 (single rear wheels) • F32 — F-350 Regular Cab, 4x2 (dual rear wheels) • F33 — F-350 Regular Cab, 4x4 (dual rear wheels) • X32 — F-350 SuperCab, 4x2 (dual rear wheels) • X33 — F-350 SuperCab, 4x4 (dual rear wheels) • W32 — F-350 Crew Cab, 4x2 (dual rear wheels) • W33 — F-350 Crew Cab, 4x4 (dual rear wheels) • F34 — F-350 Chassis Cab (Regular Cab), 4x2 (single rear wheels) • F35 — F-350 Chassis Cab (Regular Cab), 4x4 (single rear wheels) • X34 — F-350 Chassis Cab (SuperCab), 4x2 (single rear wheels) • X35 — F-350 Chassis Cab (SuperCab), 4x4 (single rear wheels) • W34 — F-350 Chassis Cab (Crew Cab), 4x2 (single rear wheels)

• W35 — F-350 Chassis Cab (Crew Cab), 4x4 (single rear wheels) • F36 — F-350 Chassis Cab (Regular Cab), 4x2 (dual rear wheels) • F37 — F-350 Chassis Cab (Regular Cab), 4x4 (dual rear wheels) • X36 — F-350 Chassis Cab (SuperCab), 4x2 (dual rear wheels) • X37 — F-350 Chassis Cab (SuperCab), 4x4 (dual rear wheels) • W36 — F-350 Chassis Cab (Crew Cab), 4x2 (dual rear wheels) • W37 — F-350 Chassis Cab (Crew Cab), 4x4 (dual rear wheels) • F46 — F-450 Chassis Cab (Regular Cab), 4x2 (dual rear wheels) • F47 — F-450 Chassis Cab (Regular Cab), 4x4 (dual rear wheels) • W46 — F-450 Chassis Cab (Crew Cab), 4x2 (dual rear wheels) • W47 — F-450 Chassis Cab (Crew Cab), 4x4 (dual rear wheels) • F56 — F-550 Chassis Cab (Regular Cab), 4x2 (dual rear wheels) • F57 — F-550 Chassis Cab (Regular Cab), 4x4 (dual rear wheels) • W56 — F-550 Chassis Cab (Crew Cab), 4x2 (dual rear wheels) • W57 — F-550 Chassis Cab (Crew Cab), 4x4 (dual rear wheels) • F53 — Recreational Stripped Chassis (Motorhome)

The eighth VIN position is the engine displacement and number of cylinders.

• S — 6.8L SOHC, EFI, V10, Gas • F — 7.3L OHV, DI Turbo, V8, Diesel • 2 — 4.2L OHV, EFI, V6, Gas • L — 5.4L, 2V, SOHC, EFI, V8, Gas

The ninth VIN position is a check digit.

The tenth VIN position is the model year code.

• X — 1999

The eleventh VIN position is the assembly plant code.

• S — Allen Park (Allen Park, Michigan) • E — Kentucky Truck (Jefferson County, Kentucky) • J — IMMSA (Monterrey, Mexico) • M — Cuautitlan (Cuautitlan, Mexico)

The last six VIN positions are an alphanumeric code for the vehicle build sequence. This is also the vehicle serial and warranty number.

• A00001-E99999

Vehicle Certification (VC) Label

Item Description

1 Exterior Paint Code

2 Region Code

3 Domestic Special Order Code

4 Wheel Base Code

5 Brake Code

6 Interior Trim Code

7 Tape/Paint Pinstripe Code

8 Radio Code

9 Axle Code

10 Transmission Code

11 Spring Code

The vehicle certification (VC) label contains the manufacturer name, the month and year of manufacture, the certification statement, and the VIN. It also includes gross vehicle weight ratings (GVWR).

Vehicle Certification (VC) Label — Canada (Typical)

Vehicle Certification (VC) Label — Mexico (Typical)

Vehicle Certification (VC) Label — Incomplete Vehicle (Typical)

Paint Codes

Refer to the paint manufacturer code book for information.

Radio Codes

• 7 — AM/FM stereo with clock • 9 — AM/FM stereo cassette and clock • K — AM /FM stereo cassette with CD player • Y — Delete standard radio with clock • G — Delete radio chassis only, AM/FM stereo, all other components installed • R — Delete radio chassis only, AM/FM cassette, all other components installed • E — Install Unique Gulf Coast Country Radio

Axle Codes

The following lists the gear ratios on rear axles.

• 31 — 3.73 non-limited slip, F-250, single rear wheels • 32 — 4.10 non-limited slip, F-250, single rear wheels • 33 — 4.30 non-limited slip, F-250, single rear wheels • 36 — 4.56 non-limited slip, F-250, single rear wheels • C1 — 3.73 limited slip, F-250, single rear wheels • C2 — 4.10 limited slip, F-250, single rear wheels • C3 — 4.30 limited slip, F-250, single rear wheels • C6 — 4.56 limited slip, F-250, single rear wheels • 41 — 3.73 non-limited slip, F-350, single rear wheels • 42 — 4.10 non-limited slip, F-350, single rear wheels • 43 — 4.30 non-limited slip, F-350, single rear wheels • 46 — 4.56 non-limited slip, F-350, single rear wheels • D1 — 3.73 limited slip, F-350, single rear wheels • D2 — 4.10 limited slip, F-350, single rear wheels • D3 — 4.30 limited slip, F-350, single rear wheels • D6 — 4.56 limited slip, F-350, single rear wheels • 61 — 3.73 non-limited slip, F-350, dual rear wheels • 62 — 4.10 non-limited slip, F-350, dual rear wheels • 63 — 4.30 non-limited slip, F-350, dual rear wheels • 66 — 4.56 non-limited slip, F-350, dual rear wheels • F1 — 3.73 limited slip, F-350, dual rear wheels • F2 — 4.10 limited slip, F-350, dual rear wheels • F3 — 4.30 limited slip, F-350, dual rear wheels • F6 — 4.56 limited slip, F-350, dual rear wheels • 81 — 3.73 non-limited slip, F-350, narrow frame, dual rear wheels • 82 — 4.10 non-limited slip, F-350, narrow frame, dual rear wheels • 83 — 4.30 non-limited slip, F-350, narrow frame, dual rear wheels • 86 — 4.56 non-limited slip, F-350, narrow frame, dual rear wheels • 88 — 4.88 non-limited slip, F-350, narrow frame, dual rear wheels • E1 — 3.73 limited slip, F-350, narrow frame, dual rear wheels • E2 — 4.10 limited slip, F-350, narrow frame, dual rear wheels • EW — 4.10 limited slip, F-350, narrow frame, dual rear wheels • E3 — 4.30 limited slip, F-350, narrow frame, dual rear wheels • E6 — 4.56 limited slip, F-350, narrow frame, dual rear wheels

• 78 — 4.88 non-limited slip, F-450, Chassis Cab, dual rear wheels • 75 — 5.38 non-limited slip, F-450, Chassis Cab, dual rear wheels • G8 — 4.88 limited slip, F-450, Chassis Cab, dual rear wheels • G5 — 5.38 limited slip, F-450, Chassis Cab, dual rear wheels • GW — 4.10 limited slip, F-450, Chassis Cab, dual rear wheels • 98 — 4.88 non-limited slip, F-550, Chassis Cab, dual rear wheels • 95 — 5.38 non-limited slip, F-550, Chassis Cab, dual rear wheels • K8 — 4.88 limited slip, F-550, Chassis Cab, dual rear wheels • K5 — 5.38 limited slip, F-550, Chassis Cab, dual rear wheels • KW — 4.10 limited slip, F-550, Chassis Cab, dual rear wheels • 75 — Dana 80, 11,000 pounds GVWR, F53 Recreational Stripped Chassis, Motorhome • 95 — Dana 135, 13,500 pounds GVWR, F53 Recreational Stripped Chassis, Motorhome

Transmission Codes

• B — Four-speed manual, T199, (Mexico) • W — Five-speed manual, heavy-duty overdrive (Dana ZF) • E — Four-speed automatic overdrive (4R100) • 6 — Six-speed manual ZF (M6HD-6) • M — Five-speed manual overdrive Mazda (M5R2-C) • E — Automatic (4R100) Expedition/Navigator (5.4L engine), F53 Recreational Stripped

Chassis, Motorhome

Spring Codes

The following lists available spring codes.

Front Springs

• Base part number — 5310 (RH/LH)

Rear Springs

• Base part number — 5560 • C — 5588, auxiliary rear spring • D — 5588, auxiliary rear spring

Interior Trim Codes

The following lists the interior trim and interior color codes.

Interior Trim

• V — Vinyl bench • K — Knitted vinyl bench • C — Cloth bench • F — Flight bench (Mexico only) • M — Full bench (Mexico only)

• 3 — Cloth 40/20/40 • 8 — Leather 40/20/40 • 2 — Cloth captains chairs • 4 — Leather captains chairs • 5 — Leather quad captains chairs

Interior Color Codes

• X — Medium Prairie Tan • 2 — Medium Graphite • D — Denim Blue

Tape Stripe Codes

• S — Silver Metallic/Dark Violet/Bright Green (XLT) • V — Prairie Tan/Dark Violet/Burnt Orange (Lariat) • W — Cordovan (Super Crew Appearance Package) • X — Ebony/Dark Violet/Burnt Orange (Lariat) • D — Silver Metallic/Medium Platinum Metallic (XL and XLT)

SECTION 100-02: Jacking and Lifting


Jacking

Lifting

SECTION 100-02: Jacking and Lifting 1999 F-Super Duty 250-550 Workshop Manual


Jacking

Jacking Points

WARNING: Do not run the engine when jacking the vehicle. The wheels contacting the ground could cause the vehicle to move.

WARNING: Make sure the jack is properly located to prevent the vehicle from falling.

Refer to the Owner Guide for additional information on vehicle jacking.

SECTION 100-02: Jacking and Lifting 1999 F-Super Duty 250-550 Workshop Manual


Lifting

WARNING: When raising a vehicle on a twin-post hoist, use extreme care positioning the hoisting forks to avoid interference with the plastic midship fuel tank.

CAUTION: When raising a vehicle on a twin-post hoist, use care when positioning the vehicle so that the hoisting forks do not interfere with the shock absorber mounting brackets or stabilizer mounting brackets, if so equipped, or damage the axle carrier or rear cover.

CAUTION: Damage to suspension, exhaust and steering linkage components can occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle.

Hoist adapters for heavy-duty hoists must be positioned according to the hoist manufacturer's recommendations. Be sure the hoist has an adequate lifting capacity for the vehicle being lifted.

Frame — Right Rear

Frame — Right Front

Frame — Left Front

Front Lifting Points — Motorhome

Suspension — Rear

Suspension — Rear, Motorhome

Lifting Points

CAUTION: When raising a vehicle on a twin-post hoist, use care when positioning the vehicle so that the hoisting forks do not interfere with the shock absorber mounting brackets or stabilizer mounting brackets, if so equipped, or damage the axle carrier or rear cover.

CAUTION: Damage to suspension, exhaust and steering linkage components can occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle.

Hoist adapters for heavy-duty hoists must be positioned according to the hoist manufacturer's recommendations. Be sure the hoist has an adequate lifting capacity for the vehicle being lifted.

SECTION 100-04:

Noise, Vibration and Harshness


Noise, Vibration and Harshness (NVH)

Definitions

Normal Noise, Vibration and Harshness

Diagnostic Theory

Glossary of Terms

DIAGNOSIS AND TESTING


Inspection and Verification

How to Use the Diagnostic Procedure

Diagnostic Procedure

Noise Diagnostic Procedure

Weight Distribution

Road Test

Hoist Test

Accessories Mounting Inspection

Axle Inspection

Drive Belt Inspection

Driveshaft Inspection

Driveshaft U-Joint Inspection

Exhaust System Inspection

Tire/Wheel Inspection

Transfer Case Inspection

Symptom Chart

Pinpoint Tests

GENERAL PROCEDURES

Powertrain/Drivetrain Mount Neutralizing

Exhaust System Neutralizing

SECTION 100-04: Noise, Vibration and

Harshness 1999 F-Super Duty 250-550 Workshop

Manual



Definitions

Noise is any unwanted sound, usually unpleasant in nature. Possible sources of noise are:

• the engine. • the engine accessories. • the intake and exhaust systems. • the driveline. • electric motors and pumps. • the wind. • mechanical pumps. • the road surface.

Vibration is an unwanted periodic motion of a body or medium. It may be felt, heard, or seen. Possible sources of vibration include the:

• tires. • engine. • engine accessories. • suspension. • driveline. • exhaust system.

Harshness refers to the ride quality and is very subjective. Reference to the previous conditions is usually the only way to identify harshness as a symptom.

Normal Noise, Vibration and Harshness

All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise and vibration that are not subject to control. Vibration isolators, mufflers and dampers are used to reduce these to acceptable levels.

A driver who is unfamiliar with a vehicle may think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, four-wheel drive vehicles and vehicles with Traction-Lok® differentials produce noise when driven on hard surfaces that does not result on two-wheel drive vehicles or on surfaces where wheel slip can occur.

As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive, it is important to test drive in and out of overdrive mode.

Diagnostic Theory

The shortest route to an accurate diagnosis results from:

• system knowledge, including comparison with a known good system. • system history, including repair history and usage patterns. • condition history, especially any relationship to repairs or sudden change. • knowledge of probable causes. • using a systematic diagnostic method that divides the system into related areas.

The diagnosis and correction of noise, vibration and harshness concerns requires:

• a road test to determine the exact nature of the concern. • an analysis of the possible causes. • testing to verify the cause. • repairing any concerns found. • a road test to make sure the concern has been corrected or brought back to within a

normal range.

Glossary of Terms

Acceleration

The act or process of increasing speed. Acceleration occurs at light, medium, or wide-open throttle (WOT) conditions.

Light Acceleration

An increase in speed at less than half throttle.

Medium Acceleration

An increase in speed at half to nearly full throttle.

WOT Acceleration

An increase in speed at wide-open throttle.

Ambient Temperature

The surrounding or prevailing temperature.

Articulation

The relative movement of attached components.

Belt Chirp

A high-pitched short-duration noise usually caused by belt misalignment.

Belt Squeal

A high-pitched long-duration noise usually caused by belt slippage.

Boom

A low-frequency (sometimes cycling) noise, often felt as well as heard.

Bound Up

A stressed isolation mount or component that transmits vibration instead of dampening or isolating it.

Brakes Applied

The use of the brakes to keep the vehicle from moving.

Camber

The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle.

Caster

The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle.

Chuckle

The noise that occurs during the coast driving phase, usually caused by excessive clearance due to differential gear wear or by a damaged tooth on the coast side of the final drive ring gear.

Clunk

A short-duration, dull sound, usually associated with the transmission engaging in reverse or drive, or heard upon initial drive-away.

Coast/Deceleration

The vehicle is in motion and the transmission is engaged, but no pressure is applied to the accelerator pedal. Speed control, if equipped, is disengaged.

Coast/Neutral Coast

The vehicle is in motion with the transmission disengaged.

Controlled Rear Suspension Height

The height that a designated vehicle element must be at when driveline angle measurements are made.

Coupling Shaft

The front shaft in a two-piece driveline system.

CPS

Cycles per second.

Cruise

Constant speed on level ground; neither accelerating nor decelerating.

Deceleration

Slowing of the vehicle by releasing the accelerator pedal, but without using the brakes.

Drive Engine Run-Up Test

The operation of the engine through the normal rpm range with the vehicle standing still and the transmission engaged. This test is used for vibration checks.

Driveline Angles

The differences of alignment between the transmission output shaft, the driveshaft (4602), and the rear axle pinion centerline.

Driveshaft

The shaft that transmits power to the axle input shaft (pinion shaft). In a two-piece driveline, it is the rearmost shaft.

Drivetrain

All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the driveline, and the drive axle.

Drivetrain Damper

A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration.

Dynamic Balance

The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side to side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Refer to Section 204-04 for the appropriate balancing procedures.

Engine Imbalance

An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases.

Engine Shake

A condition in which an engine's mass center is not concentric to the rotation center.

Engine Misfire

When ignition in one or more cylinders does not occur or occurs at the wrong time.

Flexible Coupling

A flexible joint in the exhaust pipe located between the catalytic converter and muffler, designed to eliminate binding conditions in the exhaust system and eliminate exhaust NVH.

Float

A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed.

Gravelly Feel

A grinding or growl in a component, similar to the feel experienced when driving on gravel.

Harshness

A firmer-than-usual response of a component.

Hose Clamp

A screw-type circular clamp.

Hz

Hertz; a frequency of one cycle per second.

Imbalance

Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration.

Inboard

Toward the vehicle centerline.

In-Phase

The in-line relationship between the forward coupling shaft yoke and the driveshaft centering socket yoke of a two-piece driveline.

Isolate

To separate from the influence of other components.

Knock

The noise caused by gear tooth damage on the drive side of the final drive ring gear, and also by the relative motion of components that are supported by bearings.

Neutral Engine Run-Up Test

The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations.

Neutralize/Normalize

To relieve stress from possible bound-up components.

NVH

Noise, vibration and harshness.

Outboard

Away from the centerline of the vehicle.

Pinion Shaft

The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset.

Pumping Feel

A slow pulsing movement.

Radial/Lateral

Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation.

Ring Gear

The large, circular, driven gear in a ring and pinion gearset.

Road Test

The operation of the vehicle under conditions intended to produce the concern under investigation.

Runout

Out of round or wobble.

Shake

Low frequency vibration, usually with visible movement.

Slip Yoke/Slip Spline

The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates.

Static Balance

The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Refer to Section 204-04 for the appropriate balancing procedures.

Tip-In Moan

A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph).

TIR

Total indicated runout.

Tire Deflection

The change in tire diameter in the area where the tire contacts the ground.

Tire Force Vibration

A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition may be present on perfectly round tires because of variations in the inner tire construction.

Tire Flat Spots

A condition commonly caused by letting the vehicle stand when the tires are warm. It can be corrected by driving the vehicle until the tires are warm. This concern is more likely to occur with N, V and Z-speed rated tires.

Tire wear caused by wheel-locked skids.

Two-Plane Balance

Radial and lateral balance.

Vibration

An unwanted periodic motion of a body or medium. It can be felt, heard or seen.



Manual

DIAGNOSIS AND TESTING Procedure revision date: 01/26/2000


Special Tool(s)

ChassisEAR 107-R2102 or Equivalent


This section provides a working knowledge of the process of diagnosing noise, vibration and harshness (NVH) conditions. The topics are based on the description of the condition. For example, if the condition is a shake that occurs at high speed, the most likely place to start is under High-Speed Shake in the symptom chart. The road test procedure will help you to sort the conditions into categories and distinguish a vibration from a shake. It also provides quick checks to help pinpoint or eliminate a cause.

How to Use the Diagnostic Procedure

Begin with the customer interview. Use the Glossary of Terms to find the descriptive name of conditions not encountered before. After naming it, identify the condition by performing a road test. Then, locate the proper diagnosis. Remember, by beginning at that point, most other systems in the vehicle have been eliminated; when the proper method of diagnosis is identified, the job is partly done. Follow the steps within the diagnostic procedure. Quick checks are described within the steps, while more involved procedures and adjustments are found in the General Procedures portion of this section. Always follow each step exactly and make notes along the way to recall important findings later.

Diagnostic Procedure

1: Customer Interview

It is important to interview the customer. Customer feedback can supply information that could be helpful in diagnosing the concern. Ask questions like:

• When is the concern present (at idle or while driving; at cold or warm operating temperatures; at high or low ambient temperatures)?

• Where does the concern appear to be coming from? • How long has the concern been there? Has it steadily become worse? • When did the concern start? • Does the concern change with engine speed or with vehicle speed?

Use the customer concern evaluation form, shown following the last step of this procedure, to record customer concerns.

2: Duplicate the Noise Concern

Is the noise heard while bouncing the bumper of the vehicle, driving over rough road surfaces, braking, when driving, or while parked?

Typically, front underbody noise is heard while doing the static bounce test (bouncing the bumper or the vehicle). If the noise can not be duplicated with the static bounce test, or during low speed turning maneuvers, it is most likely not suspension related.

3: Isolate the Noise Concern

If the noise can be duplicated by the static bounce test, one of the following methods will help to locate the problem while doing the static bounce test.

• Use a stethoscope or ChassisEAR to determine the area of the chassis that the noise appears to be coming from.

• Place your hand on the coil spring, radius arm, or stabilizer bar. This method is sometimes misleading as the vibrations may carry from one suspension component to another.

4: Inspecting the Vehicle

While inspecting the vehicle in the general area of the source of the noise, look for the following:

• loose fasteners • worn/broken parts • excessive dirt/rust accumulation • signs of leaking fluid • debris wrapped around the driveshaft or the axle • bound-up mounts and components • mud packed behind the wheels

5: Repair of the Vehicle

Use the symptom chart to find which pinpoint test, actions or other section(s) to refer to. Also, check TSBs, OASIS/Hotline for recent techniques or known related systems concerns.

6: Test Drive the Vehicle

Repeat the method used to duplicate the problem to verify that the noise has been repaired.

7: Follow Up with the Customer

Follow up with the customer about two weeks after the repair is performed to ensure that the noise was correctly identified and repaired.

Customer Concern Evaluation Form

Noise Diagnostic Procedure

Non-Axle Noise

There are some components, that when subject to certain conditions, can produce noise similar to axle noise and must be considered while performing a road test diagnosis. The seven most common are noise from the transmission, the exhaust system, the tires, roof racks, the power steering pump, the trim mouldings, and auxiliary fluid coolers.

Be sure that none of these components are the cause of the noise concern before proceeding with an axle teardown and diagnosis.

Noise Conditions

If noise is related to a specific component or system, refer to the appropriate workshop manual section for further diagnosis.

Vibration Conditions

Technically, vibration is a low- to high-frequency excitation, shaking or grounding condition, felt or heard, that is steady or variable in level and occurs during a portion of the total operating speed range. The types of vibrations that can be felt in the vehicle are divided into three groups:

• Vibrations of various unbalanced rotating parts of the vehicle. • Body and frame vibrations excited by powertrain, wind, or road inputs. • Tip-in moans or resonance vibrations from stressed engine, exhaust system mounts, or

driveline flexing modes.

These vehicle vibrations can also be subdivided into those that occur at low speeds and those that are most noticeable at higher speeds. Since the line between lower and higher speed vibrations is not clear, there will be vibrations that overlap the two ranges.

Typical Low-Speed Vibrations (Less Than 72 km/h [45 mph]):

• exhaust vibration • engine harshness/vibration • driveline vibration due to improper driveline angles or bad U-joints • power steering pump vibrations • drive belt vibrations • engine cooling fan vibration • take-off shudder (driveline concerns) • brake roughness or harshness • driveline roughness • clutch torsion vibration • excessive wheel runout

• tire flat spots • driveline slip-yoke or companion flange • components/material trapped between the body and the frame, the engine and the frame

or the engine and the body • automatic transmission clutch slippage

Typical High-Speed Vibrations (Above 72 km/h [45 mph]):

• axle and companion flange runout • driveshaft imbalance • excessive tire-wheel and rotor assembly imbalance • tire roughness due to high non-uniformity (force variation) or out-of-balance condition • rear axle pinion gear pitch line runout • excessive tire and wheel runout • components/material trapped between the body and the frame, the engine and the frame,

or the engine and the body • worn suspension components • front end accessory vibrations • exhaust vibration

Harshness is the term commonly used to describe the ride quality concern of the vehicle. A hard ride or harshness is usually caused by the tires or suspension system, namely:

• components/material trapped between the body and the frame • overinflated, wrong size, or wrong type of tire installed on the vehicle • suspension insufficiently lubricated • worn suspension components • suspension components installed with preload on the pivot point, the bearings, and the

bushings • vehicles equipped with tires that are not specified by the manufacturer (different brand

tires often give different ride qualities to the vehicle) • bent, bound-up or worn shock absorbers or shock isolators • heavy-duty components installed on the vehicle • load distribution

Other harshness conditions that effect ride quality are summarized as follows:

• Vehicle bounce — the vertical motion of a vehicle on its suspension system, front, and rear in phase. A low frequency "float"; an intermediate frequency "kick."

• Vehicle pitch — the out-of-phase vertical motion of the front and rear of the vehicle. A flat ride is considered the opposite of a pitch ride.

• Vehicle roll — the side-to-side rotation of the vehicle body about the front and the rear axles.

Weight Distribution

Weight properly distributed to front and rear axles gives the best ride and steerability, and eliminates premature failures due to overloaded axles, springs, tires, etc.

Payload distribution has a definite influence on vehicle performance. Even if the total vehicle is not loaded beyond the recommended maximum gross vehicle weight, this does not mean that individual components are not overloaded.

Overloading can be due to the improper positioning of heavy materials so that the load is centered over one rear tire or so far forward in the body that the front axle and tires are overloaded.

Unloaded or diminishing load type operations also affect the ride characteristics of a vehicle. Road vibrations and shock, for example, are not dampened in a light vehicle to the extent that they are under heavily loaded conditions.

Road Test

Noise, vibration and harshness (NVH) diagnosis must start with the customer interview and be followed by a road test.

NVH usually occurs in five areas:

• tires • engine accessories • suspension • NOTE: A gear-driven unit will produce a certain amount of noise. Some noise audible at

certain speeds or under various driving conditions is acceptable. Slight noise is not detrimental and must be considered normal.

drivetrain

• body and interior trim panels

It is important that an NVH concern be isolated into its specific area as soon as possible. The easiest and quickest way to do this is to perform a road test.

NVH Diagnostic Locator

Item Condition Possible Source

1 Noise, Driveline Vibration

Ring Gear Runout, Excessive Backlash Variation, Companion Flange Runout, Driveshaft Runout, Pinion Runout

2 Noise, High-Speed Shake

Wheel and Tire Imbalance, Runout, Non-Uniformity, Inflation, Force Variations, Flat Spots

3 Noise, High-Speed Shake

Wheel Bearing Roughness, Rotor Balance

4 Noise, Harshness Rear Suspension Wear, Damage, Misalignment, Binding, Worn/Hard Bushings

5 Vibration Driveshaft Runout, Balance, Angle, U-Joint Seizure, Wear

6 Noise, Vibration Transmission Gear Wear or Damage, Torque Converter Balance, Output Shaft Straightness, Transfer Case (4x4)

7 Noise, High-Speed Shake, Harshness

Wheel Bearing Roughness, Misadjustment, U-Joint Binding (4x4), Rotor Balance, Ball Joints

8 Noise, Harshness Front Suspension Wear, Damage, Misalignment, Steering Intermediate Shaft, Poor Sealing of Components Passing from Interior to Exterior

9 Tip-In Moan, Boom, Vibration

Engine, Mounts, Accessories, Air Cleaner, Torque Converter, Belts Binding, Loose, Misaligned, Worn or Damaged

10 Tip-In Moan, Noise Exhaust System Grounding, Binding, Bound Up Hangers, Damaged/Bent Components

1. Use the Vehicle Road Test Evaluation form shown following the last step of this procedure. Make notes on the backside of the form throughout the diagnostic routine.

2. NOTE: Do not make adjustments until a road test and a thorough visual inspection of the vehicle is performed. Do not change the tire pressure or the vehicle load. This may

reduce the condition's intensity to a point at which it cannot be identified clearly. It may also inject a new condition into the concern, preventing proper diagnosis.

Make a visual inspection as part of the preliminary diagnostic routine, writing down anything that does not look right. Note the tire pressures, but do not adjust them yet. Note leaking fluids, loose nuts/bolts, or bright spots where components are rubbing against each other. Check the cargo area for unusual loads.

3. Perform the neutral engine run-up (NERU) test. It identifies engine or exhaust-related vibrations and helps in sorting out vibrations that are found in the road test.

a. If the vehicle is equipped with a tachometer, it can be used. Otherwise, a tach must be connected.

b. Locate the vehicle away from other vehicles and walls which may reflect sound differently than a road.

c. Put the vehicle in N (neutral) or P (park) and do not set the parking brake or press on the service brake since these are not engaged in a road test.

d. Run the engine rpm up from an idle to approximately 4000 rpm and note any moans, vibrations, noises, etc., and the rpm at which they occur. Sometimes it is possible to "tune in" on these conditions by running the rpm up and down to determine a precise rpm at which they occur; in other cases they will fall over a broad range of rpm. This establishes a baseline against which driving vibrations can be measured.

e. If you suspect that the exhaust system is vibrating, hang a ring of keys or something similar from the tailpipe and listen for the rattling of the keys as the engine is run up and down.

f. When conducting the road test, refer to the results of the NERU test to distinguish vibrations and noises caused by the engine from those caused by the transmission, the driveshaft (4602), or the axle. If a vibration or noise occurs at a particular speed, try operating in another gear at the same speed. This changes the engine rpm and helps to distinguish engine induced vibrations and noises. If it occurs at a particular rpm, use different gears to test at the same rpm at different road speeds.

4. WARNING: Set both the parking brake and service brake and make sure to perform the test with enough space ahead of the vehicle to eliminate the possibility of an accident should the vehicle unintentionally lurch forward.

CAUTION: Do not conduct this test for over 30 seconds, or without periodic driving or shifting to neutral to circulate transmi ssion lubricant; otherwise the transmission will overheat causing severe damage to the automatic transmission.

Perform the drive engine run-up (DERU) test. Run the engine rpm up and down between an idle and approximately 2000 rpm with the transmission in D (drive). Note the nature of any vibrations and noises and when these concerns occur in relation to engine rpm.

Road Test Form

5. NOTE: The type of road and its surface condition are important factors in the road test. A smooth asphalt road that allows driving over a range of speeds is best. The brushed concrete road surface found on many expressways and the coarse aggregate sometimes found in concrete can mask many vehicle noises and make NVH diagnosis difficult.

Road test the vehicle and define the condition by reproducing it several times during the road test.

a. A tachometer must be used. b. Note the fuel level. Some vehicles change in their response to various excitations when

the fuel level changes. c. Try to duplicate the conditions with the customer present, particularly the speed and

throttle operation. d. Find the speed where the concern is most severe. e. Accelerate gently through this speed to a few mph above it and then coast back down a

few mph below it and note if the concern changes. f. Repeat this procedure, if necessary, to get a feeling for the behavior. Then drive about

five mph above the speed, put the transmission in NEUTRAL, and coast down. Note any change in behavior.

g. Try "floating" the driveline by backing off slightly on the throttle at the speed at which the condition occurs. The idea is to unload the axle gears and the universal joints as much as possible. If the concern does not change in all these modes of operation, the cause may be driveline imbalance since the imbalance is not changed by the throttle position.

6. Perform the road test quick checks as soon as the condition is reproduced. This will identify the proper method of diagnosis. Run through the quick checks more than once to make sure you are getting a usable result.

Road Test Quick Checks

1. 24-80 km/h (15-50 mph): With light acceleration, a moaning noise is heard and possibly a vibration is felt in the floorpan. It is usually worse at a particular engine speed and at a particular throttle setting during acceleration at that speed. It may also produce a moaning sound, depending on what component is causing it. Refer to Tip-In Moan in the symptom chart.

2. 40-72 km/h (25-45 mph): With steady to heavy acceleration or deceleration, a rumble-type noise is heard. It is very intense during heavy acceleration or deceleration and very light during cruise or neutral coast. The vibration is hard to duplicate with vehicle supported on a hoist, since the wheels are coasting free. Refer to Driveshaft Vibration in the symptom chart.

3. High Speed: With slow acceleration and deceleration or at constant speed, a shake is sometimes noticed in the steering wheel/column, seats, floorpan, trim panels or front end sheet metal. It is a low frequency vibration (around 9-15 cycles per second). It may increase when applying the brakes lightly. Refer to High-Speed Shake in the symptom chart.

4. High Speed: A vibration is felt in the floorpan or seats, with no visible shake, but with an accompanying sound or rumble, buzz, hum, drone or booming noise. It will exist in all drive modes, but may vary somewhat in acceleration, deceleration, float or coast modes. In some cases, the driveline vibration is eliminated in the float mode. Refer to Driveshaft Vibration in the symptom chart.

5. Neutral Engine Run-Up: A vibration is felt whenever the engine reaches a particular rpm either with the vehicle in motion or while the vehicle is sitting still. It can be caused by

any component from the fan back to the clutch or torque converter (7902) and by anything that turns at engine speed when the vehicle is stopped. Refer to Engine Accessory Vibration in the symptom chart.

Hoist Test

WARNING: If only one drive wheel is allowed to rotate, the speed must be limited to a maximum speedometer reading of 55 km/h (34 mph) since the actual wheel speed will be twice that indicated on the speedometer. Exceeding a speed of 55 km/h (34 mph) or allowing the drive wheel to hang unsupported can result in tire disintegration/differential failure, which can cause serious personal injury/extensive vehicle damage.

After a road test, it is sometimes useful to do a similar test on a hoist. (Use an axle hoist, not a frame hoist. An axle hoist will not change the driveline angles. If only a frame hoist is available, axle stands must be used.) Make sure the 4x4 selector is in the 2WD mode on a 4x4 vehicle.

1. WARNING: A vehicle equipped with a traction-lok® differential will always have both wheels driving. If only one wheel is raised off the floor and the rear axle is driven by the engine, the wheel on the floor could drive the vehicle off the stand or jack. Be sure both rear wheels are off the floor.

Elevate the rear wheels slightly. Check to make sure both wheels will turn.

2. Start the engine and shift the transmission into DRIVE (D). Explore the speed range of interest using the drive/cruise/float tests; refer to Road Test in this section.

3. A coast down in NEUTRAL must also be conducted. If the vehicle is free of vibration when operating at a steady indicated speed and behaves very differently in DRIVE and coast, an axle concern is likely.

Accessories Mounting Inspection

Inspect the drive belt accessories mounting brackets and hardware for loose fasteners or bad belt alignment; for additional information, refer to Section 303-05.

Axle Inspection

Check for low differential lubricant; for additional information, refer to Section 205-00, Section 205-02A, Section 205-02B, Section 205-02Dor Section 205-03for more information. During turns, the rear axle may have a chattering noise (Traction-Lok® axles only). Slight chatter noise

on slow turns after extended highway driving is considered acceptable and has no detrimental effect on the Traction-Lok® axle functions.

Drive Belt Inspection

Inspect the drive belt (8620) and pulleys for wear or damage. The automatic tensioners have belt wear indicator marks. If the indicator mark is not between the MIN and MAX marks, the drive belt is worn or an incorrect drive belt is installed. With the engine idling, check for irregular motion of the drive belt ; refer to Section 303-05 for more information.

Driveshaft Inspection

Inspect the driveshaft for any undercoating, physical damage and missing balance weights. Check for index marks (yellow paint daub marks) on the rear of the driveshaft and the axle companion flange. The paint daubs must be less than 22-1/2 degrees apart.

Driveshaft U-Joint Inspection

Place the vehicle on a frame hoist and rotate the driveshaft by hand. Check for rough operation or seized U-joints. Replace the U-joint if it shows signs of seizure, excessive wear, or improper seating; for additional information, refer to Section 205-01.

Exhaust System Inspection

Raise the vehicle on a hoist and check for broken and loose clamps and brackets. Check for damaged and bent exhaust components and for exhaust components touching the body and the frame. For additional information, refer to Section 309-00.

Tire/Wheel Inspection

Inspect the tires and the wheels for wear and damage. Check the tires for cupping and flat spots. Verify that the correct tire size and wheel rim are used. If a tire/wheel is damaged, the suspension components can suffer misalignment, abnormal wear/damage that contribute to the tire/wheel damage. For additional information, refer to Section 204-00 or Section 204-04.

Transfer Case Inspection

Inspect the transfer case for proper operation. For additional information, refer to Section 308-07A or Section 308-07B.

Symptom Chart

SYMPTOM CHART

Condition Possible Sources Action

• High-Speed Shake

• Tires/wheels. • Wheel bearings. • Suspension/steering

linkage. • Engine. • Transmission.

• GO to Pinpoint Test A.

• Brake rotors imbalance. • INSPECT for damage; for additional information, REFER to Section 206-00.

• Tip-In Moan • Air cleaner (ACL). • Engine mounts. • Exhaust.

• GO to Pinpoint Test B.

• Idle Boom/Shake/Vibration

• Engine compartment component grounding.

• Engine mounts. • Exhaust. • Drive belt and pulleys.

• GO to Pinpoint Test C.

• Engine Accessory Vibration

• Drive belt and pulleys. • Mounting hardware. • Accessories.

• For additional information, REFER to Section 303-05.

• Driveshaft Vibration

• Driveshaft — runout indexing (axle/transmission), companion flange, U-joints and balance.

• For additional information, REFER to driveline vibration in Section 205-00.

• Tire/Wheel Runout

• Imbalanced tires. • Damaged tire/wheel.

• GO to Pinpoint Test A.

• Brakes — Vibration/Shudder

• Brake pads. • Front disc brake hub

and rotors. • Brake calipers.


• Axle Noise • Improper axle lubricant level.

• Axle housing damage. • Axle

shaft/splines/bearings. • Differential

gears/bearings. • Broken ring gear bolts. • Broken gear teeth. • Incorrect clearance

between axle gears (ring and pinion).

• Pinion gear/bearings.

• For additional information, REFER to Section 205-00, Section 205-02A, Section 205-02B, Section 205-02C, Section 205-02D, Section 205-02Eor Section 205-03.

• Noise or Vibration — 4WD Vehicles

• Tires/wheels. • For additional information, REFER to Section 204-04.

• Wheel bearings. • For additional information, REFER to Section 204-01B.

• Driveshafts/U-joints/front axle companion shaft runout.


• Engine/transmission mounts.

• GO to Pinpoint Test C.

• Transfer case. • For additional information, REFER to Section 308-07A or Section

308-07B.

• Engine. • For additional information, REFER to Section 303-00.

• Transmission. • REFER to the appropriate transmission section.

• Driveshaft Joint Noise and Vibration

• Worn U-joints. • Center bearing support

driveshaft. • Worn slip yoke. • Worn/damaged

driveshaft.


• Non-Axle Noise • Grille whistle. • Trim moulding. • Aftermarket add-ons

(running boards, grounding body-to-frame, antennas, visors, bug deflectors, etc.).

• GO to Pinpoint Test E.

• Drive belt squeal or chirp.


• Tires. • For additional information, REFER to Section 204-04.

• Exhaust. • For additional information, REFER to Section 309-00.

• Transmission. • REFER to the appropriate

transmission section.

• Speed control system. • For additional information, REFER to Section 310-03.

• Power steering system. • For additional information, REFER to Section 211-00.

• Auxiliary transmission fluid cooler.


• Wheel End Vibration

• Tires/wheels. • Wheel bearing. • Brake drum/rotor

imbalance. • Engine or transmission

mounts.

• GO to Pinpoint Test D.

• Engine Run-Up Vibration

• Engine, Transmission, Exhaust.

• PERFORM the NERU and DERU tests; refer to Road Test in this section.

• Engine. • For additional information, REFER to Section 303-00.


• Exhaust. • For additional information, REFER to Section

309-00.

• Noise and Vibration While Turning; Clicking, Popping or Grinding

• Wheel bearings. • For additional information, REFER to Section 204-01B (4x4) or Section 206-03 (4x2).

• Brake components. • For additional information, REFER to Section 206-00.

• Suspension components.


• Steering components. • For additional information, REFER to Section 211-00.

• Shudder, Vibration During Acceleration

• Driveline angles out of specification.

• CHECK the driveline angles; for additional information, REFER to Section 205-00. CORRECT as necessary.

• Binding, damaged or galled splines on the slip yoke.

• CHECK the transmission for proper lubricant. CLEAN and lap the splines. LUBRICATE the splines with Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.

• U-joints binding or seized.


• Rear spring U-bolt. Axle assembly mispositioned.

• CHECK the U-bolts for proper torque. CHECK the axle mounts for damage and wear. REPAIR as necessary.

• Front suspension components.


• Whistle • Body system. • For additional information, REFER to Section 501-00.

• Wind Noise or Rattle

• Body system. • Exterior

trim/ornamentation. • Interior

trim/ornamentation. • Instrument panel. • Door.

• For additional information, REFER to the appropriate section in Group 5.

Pinpoint Tests

These pinpoint tests are designed to take the technician through a step-by-step diagnosis procedure to determine the cause of a condition. It may not always be necessary to follow a chart to its conclusion. Perform only the steps necessary to correct the condition. Then check the operation of the system to make sure the condition has been corrected. It is sometimes necessary to remove various vehicle components to gain access to the component to be tested. Refer to the applicable section for removal and installation of components. After verifying that the condition has been corrected, make sure all components removed have been installed.

PINPOINT TEST A: HIGH-SPEED SHAKE

CONDITIONS DETAILS/RESULTS/ACTIONS

A1 ROAD TEST FOR SHAKE/VIBRATION

Accelerate the vehicle to the speed at which the shake/vibration occurred.

Record the critical vehicle speed and engine rpm.

Place the transmission in neutral and allow the engine to return to idle.

• Does the shake/vibration disappear during the neutral coast?

→ Yes PERFORM the neutral engine run-up (NERU) test and the Drive Engine Run-Up (DERU) test; for additional information, REFER to Road Test in this section. → No GO to A2.

A2 INSPECT THE TIRES AND THE WHEELS

Raise and support the vehicle; for additional information, refer to Section 100-02.

2. Inspect the tires and the wheels for extreme wear and damage. Inspect the tires for cupping and flat spots.

• Is the condition of the tires and the wheels OK?

Yes GO to A3.

No

CHECK the suspension components for misalignment, abnormal wear and damage; for additional information, REFER to Section 204-00. CORRECT the suspension concerns and REPLACE the worn/damaged tires and wheels. PERFORM a road test.

A3 CHECK THE WHEEL BEARINGS

1. Spin the tires by hand to check for wheel bearing roughness. Check wheel bearing end play.

• Are the wheel bearings OK?

→ Yes GO to A4. → No REPLACE the wheel bearings as required; for additional information, REFER to Section 204-01B (4x4) or Section 206-03 (4x2). PERFORM a road test.

A4 CHECK THE TIRE AND WHEEL BALANCE

Check the tire and wheel balance.

• Are the tires and wheels balanced?

→ Yes GO to A5. → No BALANCE the tires and wheels; for additional information, REFER to Section 204-04. PERFORM a road test.

A5 MEASURE RUNOUTS

For each wheel position measure, locate and mark:

� high point of tire and wheel assembly total radial runout.

� high point of wheel radial runout. � high point of wheel lateral runout.

2. Record all measurements in the chart.

Assembly Position

Tire/Wheel Assembly

Total Radial Runout

Wheel Radial Runout

Wheel Lateral Runout

Left Front

Right Front

Left Rear

Right Rear

Example 1.52 mm (0.060 Inch)

0.50 mm

(0.020 Inch)

0.63 mm

(0.025 Inch)

• Have all the tire and wheel assemblies been measured?

→ Yes GO to A6. → No COMPLETE Step A5.

A6 ANALYZE THE RUNOUT MEASUREMENTS

1. Measurements obtained in Step A5 must fall within the specifications listed in Condition 1 in the following chart.

Condition

Assembly Total Radial Runout

Wheel Radial Runout

Wheel Lateral Runout

1 Less Than 1.02 mm

(0.04 Inch)

Less Than 1.14 mm

(0.045 Inch)

Less Than 1.14 mm

(0.045 Inch)

2 Less Than 1.02 mm

(0.04 Inch)

More Than 1.14 mm

(0.045 Inch)

Less Than 1.14 mm

(0.045 Inch)

3 Less Than 1.02 mm

(0.04 Inch)

Less Than 1.14 mm

(0.045 Inch)

More Than 1.14 mm

(0.045 Inch)

4 More Than

1.02 mm (0.04 Inch)

Less Than 1.14 mm

(0.045 Inch)

Less Than 1.14 mm

(0.045 Inch)

• Do the measurements obtained in A5 fall within the specifications listed in Condition 1 in the chart?

→ Yes Condition 1: Good assembly. GO to A11 . → No If Condition 2 or 3, GO to A7 . If Condition 4, GO to A8 .

A7 REPLACE THE WHEEL

1. Measure the runout on the new tire and wheel assembly.

• Is the assembly within specification from A6?

→ Yes GO to A10. → No If Condition 2 or 3, REPLACE the wheel and RECHECK. If Condition 4, GO to A8 .

A8 INDEX THE TIRE AND WHEEL ASSEMBLY

1. Align the high point of total assembly radial runout 180 degrees away from the high point of the wheel radial runout.

2. Measure the total assembly radial runout.

• Is the total radial runout less than 1.02 mm (0.04 inch)?

→ Yes GO to A10. → No GO to A9.

A9 REPLACE THE TIRE

1. Measure the total assembly radial runout on the new tire assembly.

• Is the total radial runout less than 1.02 mm (0.04 inch)?

→ Yes GO to A10. → No INDEX the tire and wheel assembly as in A8. If the new assembly is now within specification GO to A10 . If the new assembly is still not within specification, GO to A11 .

A10 ROAD TEST

1. Balance the new tire and wheel assembly.

2. After all assemblies have been checked and corrected, road test the vehicle.

• Is the vehicle operating correctly?

→ Yes Vehicle is OK. → No GO to A11.

A11 SUBSTITUTE WHEELS AND TIRES

1. Substitute a known good set of wheels and tires.

2. Road test the vehicle.

3. If the vehicle exhibits a shake or vibration, note the vehicle speed and engine rpm at which it occurs.

• Is the vibration present?

→ Yes For additional information, REFER to driveline vibration in Section 205-00. → No INSTALL the original tire and wheel assemblies one by one, road testing at each step until the damaged tire(s) is identified. REPLACE tire(s) as necessary and RETEST.

PINPOINT TEST B: TIP-IN MOAN


B1 CHECK THE ENGINE AIR CLEANER INSTALLATION

1. For additional information, refer to Section 303-12 for proper installation of the engine air cleaner.

• Is the engine air cleaner properly installed?

→ Yes GO to B2. → No CORRECT the condition and PERFORM a road test. If the moan persists,

GO to B2 .

B2 INSPECT THE ENGINE, THE TRANSMISSION MOUNTS, AND THE EXHAUST SYSTEM

WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Exhaust system leaks must be repaired immediately. Never operate the engine in an enclosed area.

WARNING: Exhaust system components are hot.

1. Inspect and replace the engine and transmission mounts as necessary.

2. CAUTION: You must neutralize the exhaust system after neutralizing the engine and transmission mounts to prevent the exhaust components from binding and introducing additional NVH into the vehicle.

Neutralize the mounts; for additional information, refer to Engine/Transmission Mount Neutralizing in this section.

3. Inspect and replace the exhaust components as necessary; for additional information, refer to Section 309-00.

4. Neutralize the exhaust system; for additional information, refer to Exhaust System Neutralizing in this section.

5. Perform a road test.

• Is moan eliminated?

→ Yes The vehicle is OK. → No For additional information, REFER to Section 303-05 for diagnosis and testing of the accessory drive system.

PINPOINT TEST C: IDLE BOOM/SHAKE/VIBRATION


C1 CHECK FOR ENGINE COMPARTMENT COMPONENT GROUNDING

1. Check the engine compartment for any component that is grounding between the engine and the body or chassis.

• Are all components OK?

→ Yes GO to C2. → No CORRECT the condition and PERFORM a road test. If the boom/shake/vibration is still present, GO to C2 .

C2 INSPECT THE ENGINE, THE TRANSMISSION MOUNTS, AND THE EXHAUST SYSTEM



NOTE: Disregard this step if it has already been performed in Step B2. GO to Section 303-05 for diagnosis and testing of the accessory drive system.

1. Inspect and replace the engine and the transmission mounts as necessary.

2. CAUTION: You must neutralize the exhaust system after neutralizing the engine and transmission mounts to prevent the exhaust components from binding and introducing additional NVH into the vehicle.

Neutralize the mounts; for additional information, refer to Engine/Transmission Mount Neutralizing in this section.

3. Inspect and replace the exhaust components as necessary; for additional information, refer to Section 309-00.



• Is the condition corrected?

→ Yes The vehicle is OK. → No For additional information, REFER to Section 303-05 for diagnosis and testing of the accessory drive system.

PINPOINT TEST D: WHEEL END VIBRATION


D1 ROAD TEST FOR VIBRATION/SHUDDER

1. Determine if the vibration/shudder is induced when making a light stop by applying the service brakes.

• Is the vibration/shudder present?

→ Yes INSPECT the brake system; for additional information, REFER to Section 206-00. → No GO to D2.

D2 PERFORM A NEUTRAL COAST TEST

Start the Engine

2. Accelerate to the maximum legal speed.

3. Allow the engine to return to idle. If the vibration exists with the transmission in NEUTRAL, the source is probably in the wheels, the tires, or the driveline.

• Does the vibration disappear during the neutral coast test?

→ Yes PERFORM the neutral engine run-up (NERU) and the drive engine run-up (DERU) tests; for additional information, REFER to Road Test in this section. → No For additional information, REFER to Section 204-04 for diagnosis and testing of the wheels and tires.

PINPOINT TEST E: NON-AXLE NOISE


E1 INSPECT THE VEHICLE TRIM

1. Inspect the grille and trim mouldings to see if they are the source of the noise; for additional information, refer to Section 501-08.

• Are the vehicle trim components causing the noise?

→ Yes REPLACE or REPAIR as necessary; for additional information, REFER to Section 501-08. → No GO to E2.

E2 CHECK FOR NON-FACTORY ACCESSORIES

Check for non-factory accessories as the source of the noise. Example: running boards grounding the body to the frame, antennas, visors, bug deflectors, etc.

• Are any accessories the cause of the noise?

→ Yes ADJUST, REPAIR, or REPLACE the accessories/fasteners as required. → No GO to E3.

E3 CHECK FOR ENGINE/TRANSMISSION NOISE

1. Perform the Road Test in this section.

• Is the noise engine speed related?

→ Yes For additional information, REFER to Section 303-00 for general engine, or to the appropriate transmission section. → No GO to the Symptom Chart.



Manual

GENERAL PROCEDURES Procedure revision date: 01/26/2000

Powertrain/Drivetrain Mount Neutralizing

CAUTION: You must neutralize the exhaust system after neutralizing the engine and transmission mounts to prevent the exhaust components from binding and introducing additional NVH into the vehicle.

1. Raise and support the vehicle; for additional information, refer to Section 100-02.

2. Loosen, but do not remove, the engine and transmission mount fasteners.

3. Lower the vehicle.

4. Operate the vehicle in forward and reverse.

5. Raise and support the vehicle.

6. Tighten the engine and transmission mount fasteners.




Manual


Exhaust System Neutralizing



NOTE: Neutralize the exhaust system to relieve strain on mounts which may be sufficiently bound up to transmit vibration as if grounded.

1. CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can be the cause of a strain problem.


2. Loosen all hanger attachments and reposition the hangers until they hang free and straight.

3. Loosen all flange joints.

4. Tighten all the hanger clamps and flanges (tighten the manifold flange joint last); for additional information, refer to Section 309-00.

• Verify adequate clearance to prevent grounding at any point in the system. • After neutralization, the rubber in the exhaust hangers should show some

flexibility when movement is applied to the exhaust system.



GROUP 04: Suspension

SECTION 204-00: Suspension System — General Information

SECTION 204-01A: Front Suspension — 4x2

SECTION 204-01B: Front Suspension — 4x4

SECTION 204-02: Rear Suspension

SECTION 204-04: Wheels and Tires

SECTION 204-00:

Suspension System — General Information

SPECIFICATIONS


Wheel Alignment Angles

Camber

Caster

Toe

Ride Height

Wheel Track

Dogtracking

Wander

Shimmy

Nibble

Poor Returnability/Sticky Steering

Drift/Pull


Suspension System


Symptom Chart

Component Tests

GENERAL PROCEDURES

Wheel Bearing Inspection

Camber Adjustment—F-250, F-350, 4x4 and F-450, F-550

Caster Adjustment—Motorhome

Caster Adjustment—F-250, F-350, 4x4 and F-450, F-550

Camber and Caster Adjustment—F-250 and F-350, 4x2

Toe Adjustment—Motorhome

Toe Adjustment—F-250 and F-350, 4x2

Toe Adjustment—F-250, F-350, 4x4 and F-450, F-550

Lean Correction—Front, F-250 and F-350, 4x2

Lean Correction—Front, F-250, F-350, 4x4 and F-450, F-550

Lean Correction—Rear

Lean Correction—Motorhome

SECTION 204-00: Suspension System — General

Information 1999 F-Super Duty 250-550

Workshop Manual

SPECIFICATIONS Procedure revision date: 01/26/2000

General Specifications

Item LH RH Total/Split

Alignment Specifications — F-250 and F-350, 4x2

Caster @ Curb Ride Height 4.0° ± 2° 4.0° ± 2° 0° ± 1°

Camber @ Curb Ride Height 0.62° ± 1° 0.62° ± 1° 0° ± 1°

Toe @ Curb Ride Height (Positive Value Is Toe-In, Negative Value Is Toe-Out)

— — 0.03° ± 0.25°

Steering Axis Inclination (SAI) @ Full Load — — 12.3°

Included Angle @ Full Load — — 12.3°

Alignment Specifications — F-250 and F-350, 4x4




— — 0.03° ± 0.25°



Alignment Specifications — F-450 and F-550, 4x2 and 4x4




— — 0.03° ± 0.25°



Alignment Specifications — Motorhome

Caster @ Curb Ride Height 4.63° ± 0.5°

4.63° ± 0.5°

0° ± 0.25°

Camber @ Curb Ride Height 1.0° ± 0.375°

1.0° ± 0.375°

0° ± 0.375°


— — 1/16 In ± 1/32 In

Steering Axis Inclination (SAI) — — 5.52°


Item Specification

Dogtracking — Motorhome

Dogtracking — Maximum (Centerline of front tires compared to centerline of rear tires)

9 mm (0.375 in.)

Dogtracking — F-250, F-350, F-450, and F-550

Dogtracking — Maximum (Centerline of front tires compared to centerline of rear tires)

30 mm (1.2 in)

Clear Vision — F-250, F-350, F-450, and F-550

Clear Vision (Negative value is counterclockwise) -0.4° ± 3°

Clear Vision — Motorhome

Clear Vision (Negative value is counterclockwise) 0° ± 5°

Curb Ride Height — F-250, 4x2

Front 110-124 mm (4.3-4.9 in.)

Rear — Standard Suspension 157-219 mm (6.2-8.6 in.)

Rear — Heavy Duty Suspension 144-206 mm (5.7-8.1 in.)

Curb Ride Height — F-250, 4x4

Front 108-132 mm (4.25-5.20 in.)



Curb Ride Height — F-350 Pick-Up, 4x2, Single Rear Wheel

Front 110-124 mm (4.3-4.9 in.)



Curb Ride Height — F-350 Pick-Up, 4x4, Single Rear Wheel

Front 108-132 mm

(4.25-5.20 in.)



Curb Ride Height — F-350 Pick-Up, 4x2, Dual Rear Wheel

Front 110-124 mm (4.3-4.9 in.)

Rear — Ford Axle with Standard Suspension 164-226 mm (6.5-8.9 in.)

Rear — Ford Axle with Heavy Duty Suspension 151-213 mm (5.9-8.4 in.)

Rear — Dana Axle with Standard Suspension 164-226 mm (6.5-8.9 in.)

Rear — Dana Axle with Heavy Duty Suspension 151-213 mm (5.9-8.4 in.)

Curb Ride Height — F-350 Pick-Up, 4x4, Dual Rear Wheel

Front 108-132 mm (4.25-5.20 in.)


Rear — Ford Axle with Heavy Duty Suspension 140-202 mm (5.5-8.0 in.)


Rear — Dana Axle with Heavy Duty Suspension 140-202 mm (5.5-8.0 in.)

Curb Ride Height — F-350 Chassis Cab, 4x2, Single Rear Wheel

Front 110-124 mm (4.3-4.9 in.)


Curb Ride Height — F-350 Chassis Cab, 4x4, Single Rear Wheel

Front 108-132 mm (4.25-5.20 in.)


Curb Ride Height — F-350 Chassis Cab, 4x2, Dual Rear Wheel

Front 110-124 mm

(4.3-4.9 in.)



Curb Ride Height — F-350 Chassis Cab, 4x4, Dual Rear Wheel

Front 108-132 mm (4.25-5.20 in.)


Curb Ride Height — F-450, 4x2 and 4x4

Front 148-172 mm (5.8-6.8 in.)

Rear 159-221 mm (6.3-8.7 in.)

Curb Ride Height — F-550, 4x2 and 4x4

Front 148-172 mm (5.8-6.8 in.)

Rear 175-237 mm (6.9-9.3 in.)

Ball Joint Radial Play

Lower Ball Joint — Maximum 0.8 mm (1/32 in.)

Upper Ball Joint — Maximum 0.8 mm (1/32 in.)

Vehicle Lean (Side-to-Side Height Differences) — F-250, F-350, F-450, F-550

Rear — Maximum 19 mm (0.75 in.)

Vehicle Lean (Side-to-Side Height Differences) — Motorhome

Front — Maximum 15 mm (0.59 in.)

Rear — Maximum 20 mm (0.78 in.)

Sealant

Threadlock and Sealer EOAZ-19554-AA WSK-M2G315-A5

(Type II)

Camber/Caster Service Adjuster — F-250 and F-350, 4x2

LH Axle RH Axle Service

Adjuster Type (Degrees)

Position Slot in Axle

(Degrees)

Camber Change

(Degrees)

Caster Change

(Degrees)

Camber Change

(Degrees)

Caster Change

(Degrees)

1/2 0 -0.5 0 +0.5 0

1 0 -1.0 0 +1.0 0

1-1/2 0 -1.5 0 +1.5 0

1/2 45 -0.25 +0.25 +0.25 +0.25

1 45 -0.75 +0.75 +0.75 +0.75

1-1/2 45 -1.0 +1.0 +1.0 +1.0

1/2 90 0 +0.5 0 +0.5

1 90 0 +1.0 0 +1.0

1-1/2 90 0 +1.5 0 +1.5

1/2 135 +0.25 +0.25 -0.25 +0.25

1 135 +0.75 +0.75 -0.75 +0.75

1-1/2 135 +1.0 +1.0 -1.0 +1.0

1/2 180 +0.5 0 -0.5 0

1 180 +1.0 0 -1.0 0

1-1/2 180 +1.5 0 -1.5 0

1/2 225 +0.25 -0.25 -0.25 -0.25

1 225 +0.75 -0.75 -0.75 -0.75

1-1/2 225 +1.0 -1.0 -1.0 -1.0

1/2 270 0 -0.5 0 -0.5

1 270 0 -+1.0 0 -1.0

1-1/2 270 0 -1.5 0 -1.5

1/2 315 -0.25 -0.25 +0.25 -0.25

1 315 -0.75 -0.75 +0.75 -0.75

1-1/2 315 -1.0 -1.0 +1.0 -1.0

Torque Specifications

Description Nm Lb/Ft

Adjusting Sleeve Clamp Nuts — F-250, F-350, F-450, F-550 55 41

Adjusting Sleeve Clamp Nuts — Motorhome 80 60

Front Spring U-Bolt Nut — F-250, F-350, 4x4 and F-450, F-550 133 99

Front Spring U-Bolt Nut — Motorhome 350 259

Lower Ball Joint Nut — F-250, F-350, 4x4 and F-450, F-550 a —

Rear Spring U-Bolt Nut — F-250, F-350 250 185

Rear Spring U-Bolt Nut — F-350 Chassis Cab 240 178

Rear Spring U-Bolt Nut — F-450 300 222

Rear Spring U-Bolt Nut — F-550 350 259

Rear Spring U-Bolt Nut — Motorhome 350 259

Upper Ball Joint Pinch Bolt — F-250 and F-350, 4x2 80 60

Upper Ball Joint Nut — F-250, F-350, 4x4 and F-450, F-550 125 93

1/4-Inch Diameter Bolts and Nuts — Grade 5 12 9

5/16-Inch Diameter Bolts and Nuts — Grade 5 20 15

3/8-Inch Diameter Bolts, U-Bolts and Nuts — Grade 8 50 37







1-Inch Diameter Bolts, U-Bolts and Nuts — Grade 5 860 634 a Refer to the procedure in this section.

SECTION 204-00: Suspension System —

General Information 1999 F-Super Duty 250-550

Workshop Manual


Wheel Alignment Angles

Super Duty Series vehicle caster and camber correction requirements are factory-determined. Adjusters are available to correct a caster/camber measurement that does not meet specification. Before changing the production caster/camber adjuster, thoroughly inspect the suspension system to locate worn or damaged components that may have caused the setting to change.

Camber

Negative and Positive Camber

Camber is the vertical tilt of the wheel (1007) when viewed from the front. Camber can be positive or negative and has a direct effect on tire wear.

Caster

Caster and Frame Angle

Item Part Number Description

1 — Positive Caster

2 — True Vertical

3 — Steering Axis

Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed from the side. The caster specifications in this section will give the vehicle the best directional stability characteristics when loaded and driven. The caster setting is not related to tire wear.

Toe

Positive Toe (Toe In)

Negative Toe (Toe Out)

The vehicle toe setting:

• affects tire wear and directional stability. • must be checked after adding aftermarket equipment, such as a snowplow or body.

Ride Height

Front Ride Height Measurement — F-250 and F-350, 4x2

Item Description

1 Ride Height Measurement — (RH)

2 Ride Height Measurement — (LH)

Front Ride Height Measurement — F-250 and F-350, 4x4, and F-450, F-550

Rear Ride Height Measurement — 4x2

Rear Ride Height Measurement — 4x4

Wheel Track


1 — Front Track

2 — Rear Track

Dogtracking


1 — Front Track

2 — Rear Track Dogtracking

Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can give the illusion of dogtracking.

Wander

Wander is the tendency of the vehicle to require frequent, random left and right steering wheel (3600) corrections to maintain a straight path down a level road.

Shimmy

Shimmy, as observed by the driver, is large, consistent, rotational oscillations of the steering wheel resulting from large, side-to-side (lateral) tire/wheel movements.

Shimmy is usually experienced near 64 km/h (40 mph), and can begin or be amplified when the tire contacts pot holes or irregularities in the road surface.

Nibble

Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various road surfaces and observed by the driver as small rotational oscillations of the steering wheel.

Poor Returnability/Sticky Steering

Poor returnability and sticky steering is used to described the poor return of the steering wheel to center after a turn or the steering correction is completed.

Drift/Pull

Pull is a tugging sensation, felt by the hands on the steering wheel, that must be overcome to keep the vehicle going straight.

Drift describes what a vehicle with this condition does with hands off the steering wheel.

• A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead path and require constant steering input in the opposite direction to counteract the effect.

• Drift/pull may be induced by conditions external to the vehicle (i.e., wind, road camber).

Poor Groove Feel

Poor groove feel is characterized by little or no buildup of turning effort felt in the steering wheel as the wheel is rocked slowly left and right within very small turns around center or straight-ahead (under 20 degrees of steering wheel turn). Efforts may be said to be "flat on center."

• Under 20 degrees of turn, most of the turning effort that builds up comes from the mesh of gear teeth in the steering gear (3504). In this range, the steering wheel is not yet turned enough to feel the effort from the self-aligning forces at the road wheel or tire patch.

• In the diagnosis of a roadability problem, it is important to understand the difference between wander and poor groove feel.



Workshop Manual


Suspension System


1. Road test. • Verify the customer's concern by performing a road test on a smooth road. If any

vibrations are apparent, for additional information, refer to Section 100-04.

2. Inspect tires. • Check the tire pressure with all normal loads in the vehicle and the tires cold;

refer to the vehicle certification (VC) label. • Verify that all tires are sized to specification; for additional information, refer to

Section 204-04. • Inspect the tires for improper wear and damage; for additional information, refer

to Section 204-04.

3. Inspect chassis and underbody. • Remove any excessive accumulation of mud, dirt or road deposits from the

chassis and underbody.

4. Inspect for aftermarket equipment. • Check for aftermarket changes to the steering, suspension, wheel and tire

components (such as competition, heavy duty, etc.) The specifications shown in this manual do not apply to vehicles equipped with aftermarket equipment.

Visual Inspection Chart

Mechanical

• Front wheel bearing(s) • Loose or damaged front or rear suspension components • Loose, damaged or missing suspension fastener(s) • Loose or damaged shackle(s) • Improper spring usage • Damaged or sagging spring(s) • Damaged or leaking shock absorber(s) • Worn or damaged suspension bushing(s) • Loose, worn or damaged steering system components

• Damaged axle components

5. If an obvious cause for an observed or reported condition is found, correct the cause (if possible) before proceeding to the next step.

6. If the fault is not visually evident, determine the symptom and proceed to the following symptom chart.

Symptom Chart

SYMPTOM CHART


• Dogtracking • Excessive rear thrust angle.

• ADJUST as necessary.

• Front or rear suspension components.

• INSPECT the front and rear suspension systems. REPAIR or REPLACE as necessary. For additional information, REFER to Section 204-01A, Section 204-01B or Section 204-02.

• Drive axle damaged.

• REPAIR as necessary. REFER to the appropriate section in Group 2.

• Drift/Pull • Unequal tire pressure.

• ADJUST tire pressure.

• Excessive side-to-side difference in caster or camber.


• Tire forces. • ROTATE tires front to rear.

• Unevenly loaded or

• NOTIFY the customer of

overloaded vehicle.

improper vehicle loading.

• Steering components.


• Brake drag. • For additional information, REFER to Section 206-00.

• Front Bottoming or Riding Low

• Front spring(s). • REPLACE any unserviceable front spring(s) as necessary. For additional information, REFER to Section 204-01A or Section 204-01B.

• Front suspension bumper(s).

• REPLACE as necessary. For additional information, REFER to Section 204-01A or Section 204-01B.

• Improper Tire Wear

• Incorrect tire pressure (rapid center rib or inner and outer edge wear).

• ADJUST tire pressure.

• Excessive front or rear toe (rapid inner or outer edge wear).


• Excessive negative or positive camber (rapid inner or outer edge wear).


• Tires out of balance (tires cupped or dished).

• BALANCE tires.

• Rear Spring Squeak

• Rear spring(s). • INSTALL new rear spring anti-squeak inserts.

• Shackle bushing(s).

• REPLACE as necessary.

• Rough Ride • Shock absorber(s).


• Spring(s). • REPLACE as necessary. For additional information, REFER to Section 204-01A, Section 204-01B or Section 204-02.

• Shimmy or Wheel Tramp

• Loose lug nut(s).

• TIGHTEN to specification. For additional information, REFER to Section 204-04.

• Loose front suspension fasteners.

• TIGHTEN to specification. For additional information, REFER to Section 204-01A or Section 204-01B.

• Front wheel bearing adjustment.

• GO to Wheel Bearing Inspection in this section.

• Wheel or tire concerns.


• Springs. • REPLACE as necessary. For additional information, REFER to Section 204-01A, Section 204-01B or Section 204-02.

• Loose, worn or damaged ball joints.

• GO to the Ball Joint Inspection component test in this section.

• Loose, worn or damage steering

• For additional information,

components. REFER to Section 211-00.

• Front wheel alignment.


• Sticky Steering, Poor Returnability

• Ball joints. • GO to the Ball Joint Inspection component test in this section.



• Front wheel alignment.


• Steering Wheel Off-Center

• Unequal front or rear toe settings (side-to-side).




• Sway or Roll • Overloaded, unevenly or improperly loaded vehicle.

• NOTIFY the customer of improper vehicle loading.

• Loose lug nut(s).

• TIGHTEN to specification. For additional information, REFER to Section 204-04.

• Shock absorber(s).


• Loose stabilizer assembly.

• TIGHTEN to specification. For additional information, REFER to Section 204-01A, Section 204-01B or Section 204-02.

• Worn stabilizer assembly

• REPLACE as necessary. For additional information, REFER to Section 204-

bushing(s). 01A, Section 204-01B or Section 204-02.

• Worn spring(s). • REPLACE as necessary. For additional information, REFER to Section 204-01A, Section 204-01B or Section 204-02.

• Vehicle Leans to One Side

• Unevenly loaded or overloaded vehicle.


• Front or rear suspension components.

• INSPECT the front and rear suspension systems. REPAIR or REPLACE as necessary. For additional information, REFER to Section 204-01A, Section 204-01B or Section 204-02.

• Spring(s). • REPLACE any unserviceable spring(s) or components as necessary. For additional information, REFER to Section 204-01A, Section 204-01B or Section 204-02.

• Incorrect ride height. Lateral tilt out of specification.

• INSPECT the rear suspension system. REPAIR or REPLACE any unserviceable rear suspension components as necessary. For additional information, REFER to Section 204-01A, Section 204-01B or Section 204-02.

• Vibration/Noise • Tires and wheel concerns.

• Wheel bearings. • Wheel hubs. • Brake


components. • Suspension

components. • Steering

components.

• Wander • Unevenly loaded or overloaded vehicle.


• Ball joint(s). • GO to the Ball Joint Inspection component test in this section.

• Loose, worn or damaged front wheel bearing(s).

• GO to Wheel Bearing Inspection in this section.

• Loose, worn or damaged suspension components(s).

• REPLACE as necessary. For additional information, REFER to Section 204-01A or Section 204-01B.

• Loose suspension fasteners.

• TIGHTEN to specification. For additional information, REFER to Section 204-01A or Section 204-01B.



• Wheel alignment (excessive total front toe out).


Component Tests

Ball Joint Inspection


2. Prior to performing any inspection of the ball joints, inspect the front wheel bearings (1216); for additional information, refer to Wheel Bearing Inspection in this section.

3. Position a safety stand beneath the front axle to be tested.

4. While an assistant pulls and pushes the bottom of the tire, observe the relative movement between the lower spindle arm and the front axle. Any movement at or exceeding the specification indicates a worn or damaged lower ball joint. Replace as necessary; for additional information, refer to Section 204-01A or Section 204-01B.

5. While an assistant pulls and pushes the top of the tire, observe the relative movement between the upper spindle arm and the front axle. Movement at or exceeding the specification indicates a worn or damaged upper ball joint. Replace the upper ball joint as necessary; for additional information, refer to Section 204-01A or Section 204-01B.



Workshop Manual


Wheel Bearing Inspection

1. Raise the vehicle until the tire is off the floor; for additional information, refer to Section 100-02.

2. NOTE: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow movement of the tire and wheel assembly.

Grasp each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing.

3. If the tire and wheel (hub) is loose on the wheel spindle or does not rotate freely, perform one of the following actions.

• On 4x2 vehicles, adjust the front wheel bearings; for additional information, refer to Section 204-01A.

• On 4x4 vehicles, replace the wheel hub (1104); for additional information, refer to Section 204-01B.



Workshop Manual


Camber Adjustment—F-250, F-350, 4x4 and F-450, F-550

Special Tool(s)

Steering Arm Remover 211-003 (T64P-3590-F)


2. Remove the front wheel; for additional information, refer to Section 204-04.

3. Check and note the amount of camber in the current camber adjuster sleeve.

4. Select a new camber adjuster sleeve. • The camber change required to obtain the optimum settings must be added or

subtracted from the amount of camber in the old or production camber adjuster sleeve.

• Use this example as a guide. If the LH wheel camber must be reduced 1 degree and the existing camber adjuster sleeve has a +5 degree of camber, select the -0.5 degree camber adjuster sleeve.

5. Remove the cotter pin and castellated nut. Discard the cotter pin.

6. Install the nut.

7. Loosen the nut to the end of the lower ball joint stud.

8. CAUTION: Use care not to damage the brake and vacuum lines when striking the spindle.

Separate the spindle from the axle.

9. Remove the nut.

10. Remove the camber adjuster sleeve. • Use the Steering Arm Remover.

11. Install the new camber adjuster sleeve.

12. Remove the nut.

13. Install the nut and tighten to initial torque. • Apply Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford

specification WSK-M2G315-A5 (Type II).

14. Install the castellated nut and a new cotter pin.

15. Tighten the nut to final torque.

16. Install the front wheel; for additional information, refer to Section 204-04.


18. Recheck the camber measurement. Readjust as necessary.



Workshop Manual


Caster Adjustment—Motorhome


2. Support the axle and the chassis independently.

3. Remove the nuts. Discard the U-bolts and nuts.

4. Lower the axle enough to insert the adjustment wedge.

5. Insert the caster adjustment wedge.

6. Install new U-bolts and nuts. Tighten the nuts. • Note the U-bolt size and tighten to specification.

7. Lower the vehicle; for additional information, refer to Section 100-02.

8. Recheck the caster.



Workshop Manual


Caster Adjustment—F-250, F-350, 4x4 and F-450, F-550


2. Remove the front wheel; for additional information, refer to Section 204-04.

3. Support the axle.

4. Remove and discard the four nuts and two U-bolts.

5. Separate the front axle from the springs.

6. Remove the existing caster adjustment shim, if necessary. • Note the amount of caster and the orientation of the existing caster adjustment

shim.

7. Select a new caster adjustment shim. • The caster change required to obtain the optimum settings must be added or

subtracted from the amount of caster in the old or productions caster adjustment shim.

• Use this example as a guide. If the LH wheel caster must be reduced 1 degree and the existing caster adjustment shim has +2 degree of caster, select the 1 degree caster adjustment shim.

8. Install the new caster adjustment shim. • To increase caster, position the thin edge of the shim toward the front of the

vehicle. • To decrease caster, position the thin edge of the shim toward the rear of the

vehicle. • Position the caster adjustment shim so the spring seat tie bolt sets through the

shim into the axle housing.

9. Install four new nuts and two new U-bolts.

10. Remove the support from the axle.



13. Recheck the caster measurement. Readjust as necessary.



Workshop Manual


Camber and Caster Adjustment—F-250 and F-350, 4x2

Special Tool(s)


1. CAUTION: Do not bend axles or radius arms to change alignment.

Using an alignment rack and manufacturer's instructions, measure the caster and camber.

• Refer to Alignment Specifications in the Specifications portion of this section for optimal alignment settings.

• Note any difference between the actual measurements and the specification. This information will be used to select the correct service adjuster.

2. Raise and support the front end; for additional information, refer to Section 100-02.

3. Remove the front wheel(s); for additional information, refer to Section 204-04.

4. Check the type and orientation of the installed adjuster. • Production adjusters have a round flange, a side tab and the amounts of caster and

camber stamped in the top of the adjuster. � The first number is the amount of caster; the second number is the amount

of camber in degrees if the adjuster is installed in the right-hand axle position.

� If the adjuster is in the left-hand axle, the caster number is the opposite sign of the number shown. For example, a positive amount in the right-hand axle is a negative amount in the left axle, and a negative amount in the right-hand is a positive in the left-hand position.

• Service adjusters have a hex flange, no side tab and the adjustment amount of the caster and camber stamped into the top.

5. NOTE: The assembly plant sometimes builds vehicles with adjusters that are not 0-degree type to control alignment. The Camber/Caster Service Adjuster chart shows the alignment changes that will occur if the vehicle was originally built with 0-degree adjusters.

Select a new service adjuster and its orientation in the axle to obtain the optimum caster/camber. Refer to the Camber/Caster Service Adjuster chart in the Specifications portion of this section.

• Note that the caster change or camber change required to obtain the optimum settings must be added to amounts of caster/camber in the old or production adjuster.

• Use this example as a guide. If caster must be reduced 1 degree and camber increased +0.75 degree at the LH wheel, and the existing adjuster has +0.25-degree caster as installed, select the 1-degree service adjuster and orient the slot 225 degrees from the straight-ahead position. In all cases, select the adjuster and orientation that will bring the alignment closest to the optimal settings.

6. Loosen the pinch bolt. Using the Steering Arm Remover, remove the adjuster from the axle.

7. Install the new service adjuster. Orient the slot as noted in Step 5. 1. Position the new adjuster as specified in the chart.

2. Tighten the pinch bolt.


9. Lower the front end; for additional information, refer to Section 100-02.

10. Check the alignment. If not at optimal caster/camber specification, additional adjustment of the rotational orientation of the adjuster is required.

11. Once optimal caster/camber has been achieved, reset the toe and clear vision to optimal settings.



Workshop Manual


Toe Adjustment—Motorhome

1. Loosen the clamp at both ends of the tie rod.

2. Rotate the tie rod to bring the toe into specification.

3. NOTE: For movable tie rod clamps, make sure the tab is against the end of the tie rod.

NOTE: Note the specification for the tie rod clamp orientation.

Tighten the clamp to specification.

4. Recheck the toe.



Workshop Manual


Toe Adjustment—F-250 and F-350, 4x2

1. Start the engine (6007) and center the steering wheel (3600).

2. Turn the engine off, and hold the steering wheel in the straight-forward position by attaching a rigid link from the steering wheel to the brake pedal.

3. Check the toe settings; follow the manufacturer's instructions.

4. Loosen the nuts. • Clean and lubricate the steering linkage and tie rod end threads.

5. Rotate the tie rod adjusting sleeves (3281) to obtain the correct toe setting.

6. Position the RH adjusting sleeve clamp opening downward within 45 degrees of vertical. Tighten the nuts.

7. Position the LH adjusting sleeve clamp opening upward within 45 degrees of vertical. Tighten the nuts.

8. Recheck the toe settings; follow the manufacturer's instructions.



Workshop Manual


Toe Adjustment—F-250, F-350, 4x4 and F-450, F-550

1. Start the engine. Center the steering wheel.

2. Turn the engine off. Use a rigid link from the steering wheel to the brake pedal to lock the steering wheel in the straight-forward position.

3. NOTE: If the RH toe measurement is within specifications and only the LH toe measurement needs adjustment, go to Step 6.

Loosen the nuts.

• Clean and lubricate the steering linkage and tie rod end threads.

4. Rotate the tie rod adjusting sleeve to the correct toe setting.

5. Tighten the nuts.

6. Loosen the nuts. • Clean and lubricate the steering linkage and tie rod end threads.

7. Rotate the tie rod adjusting sleeve to the correct toe setting.

8. Tighten the nuts.

9. Recheck the toe settings. Follow the manufacturer's instructions.



Workshop Manual


Lean Correction—Front, F-250 and F-350, 4x2

1. If lean correction is required, remove the high side front coil spring (5310); for additional information, refer to Section 204-01A.

2. Compare the height of the original front coil spring with a new one with the same part number. Note the difference.

3. If the original front coil spring exceeds the height of the new one by 13 mm (1/2 in.), install the new front coil spring in the vehicle; for additional information, refer to Section 204-01A.

4. If the original front coil spring is shorter than the new one by at least 13 mm (1/2 in.), remove the low side front coil spring from the vehicle; for additional information, refer to Section 204-01A.

5. Compare all three front coil springs and select the two most evenly matched for installation.

6. Install the tallest replacement front coil spring on the low side of the vehicle; for additional information, refer to Section 204-01A.



Workshop Manual


Lean Correction—Front, F-250, F-350, 4x4 and F-450, F-550

1. NOTE: Front side lean can be adjusted approximately 10 mm (3/8 in.) by installing shim D7TZ-5742-A on the low side. A vehicle that is low at the front can be raised by installing shims at both sides.



3. Remove and discard the four nuts and two U-bolts.

4. Separate the front axle from the springs.

5. Turn the shim so the recess is facing upward.

6. Insert the shim between the spring and the spring seat. • Position the shim so the spring tie bolt is in the shim recess, the stud on the

bottom of the shim is in the spring seat recess, and the shim is aligned with the spring.

7. Install two new U-bolts and four new nuts.



Workshop Manual


Lean Correction—Rear

1. NOTE: Rear side lean can be adjusted approximately 10 mm (3/8 in.) by installing shim D7TZ-5742-A on the low side. A vehicle that is low at the rear can be raised by installing shims at both sides.

Raise and support the vehicle frame until the weight is off the rear springs but with the tires still touching the floor; for additional information, refer to Section 100-02.


3. Remove and discard the four nuts and two U-bolts to allow the rear axle to separate from the rear spring (5560).

4. Turn the shim so the recess is facing upward.

5. Insert the shim between the rear spring and the spring seat. • Position the shim so the tie bolt through the spring leaves is in the shim recess, the

stud on the bottom of the shim is in the spring seat recess, and the shim is aligned with the rear spring.

6. Install two new U-bolts and four new nuts.





Workshop Manual


Lean Correction—Motorhome

1. CAUTION: Corrections should not be attempted on vehicles with a bumper-to-ground height right-to-left variation of 25.4 mm (1 inch) or less. Corrections should not be made if the ride height variation is 12.7 mm (1/2 inch or less).


2. Position a separate support for the front axle.

3. Raise the front axle to relieve front spring tension.

4. Remove the nuts, U-bolts and upper spacer. Discard the nuts and U-bolts.

5. Lower the front axle enough to insert the spacer.

6. NOTE: Make sure the locator pin on the bottom of the spacer is in the locator hole in the spring pad.

Position the spacer and caster adjustment wedge, if required, on the spring pad.

7. Raise the axle.

8. Install the upper spacer, new U-bolts and new nuts. • Tighten to specification.



SECTION 204-01A: Front Suspension —

4x2 1999 F-Super Duty 250-550 Workshop

Manual



Item Specification

Motorcraft Premium Long-Life Grease XG-1-C or -K

ESA-M1C75-B

Threadlock® and Sealer EOAZ-19554-AA WSK-M2G315-A5 (Type II)

Torque Specifications — F-250, F-350

Description Nm Lb/Ft Lb/In

Upper Spring Retainer Bolt-to-Spring/Shock Tower 35 26 —

Lower Spring Retainer Nut-to-Lower Spring Seat 133 99 —

Radius Arm Retainer Bolt-to-Axle/Radius Arm Retainer Nut 400 295 —

Radius Arm Pivot Bolt Retainer Nut-to-Radius Arm Bracket 250 185 —

Radius Arm Bracket-to-Frame 80 60 —

Axle Pivot Bolt Retainer Nut-to-Axle Pivot Bracket 175 130 —

Axle Pivot Bracket Nut-to-Frame 80 60 —

Shock Absorber-to-Spring/Shock Tower Nut 40 30 —

Upper Spindle Pinch Bolt Nut-to-Axle 80 60 —

Lower Spindle Nut-to-Axle a — —

Lower Shock Absorber Retainer Nut 80 60 —

Stabilizer Bar Link Nut-to-Lower Spring Seat 80 60 —

Stabilizer Bar Link Nut-to-Stabilizer Bar 80 60 —

Stabilizer Bar Retainer Bracket-to-Frame 48 36 —

Tie Rod End Retainer Nut-to-Spindle 90 67 —

Steering Damper Retainer Nut-to-Steering Damper Bracket 90 67 —

Steering Damper Retainer Nut-to-Steering Linkage Bracket 90 67 —

Steering Damper Bracket Retainer Nut-to-Frame 90 67 —

Steering Damper Bracket-to-Steering Linkage 28 21 —

ABS Sensor Retaining Bolt-to-Spindle 8 — 71

ABS Sensor Harness Retaining Bolt 8 — 71

Disc Brake Rotor Shield 8 — 71 a Follow the procedure in this section.

Torque Specifications — F-450, F-550


Front Spring Hanger Nut-to-Front Spring 350 259 —

Front Spring Hanger Bracket Bolts-to-Frame 103 76 —

Front Spring Shackle Bracket Nut-to-Front Spring 250 185 —

Front Spring Shackle Bracket Nut-to-Shackle Bracket Assembly 250 185 —

Shackle Bracket Assembly Bolt-to-Frame 90 67 —

Front Spring U-Bolt Nut-to-Axle 133 99 —

Trackbar-to-Trackbar Bracket 175 130 —

Trackbar-to-Trackbar Axle Bracket 175 130 —

Lower Shock Absorber Retaining Nut-to-Front Spring Spacer Plate 103 76 —

Upper Shock Absorber Retainer Bolt-to-Upper Shock Absorber Bracket 103 76 —

Upper Shock Absorber Bracket-to-Frame 103 76 —

Stabilizer Bar Link Nut-to-Stabilizer Bar Link Bracket 80 60 —

Stabilizer Bar Link Bracket-to-Frame 103 76 —

Stabilizer Bar Link Nut-to-Stabilizer Bar 80 60 —

Stabilizer Bar Retainer Bracket-to-Axle 47 35 —

Axle Bumper Assembly-to-Frame 40 30 —

Upper Spindle Nut-to-Axle 125 93 —

Lower Spindle Nut-to-Axle a — —

Tie Rod End Retainer Nut-to-Spindle 90 67 —

Steering Damper Retainer Nut-to-Steering Damper Bracket 90 67 —

Steering Damper Retainer Nut-to-Steering Linkage Bracket 90 67 —

Steering Damper Bracket Retainer Nut-to-Frame 90 67 —

Steering Damper Bracket-to-Steering Linkage 28 21 —

ABS Sensor Retainer Bolt-to-Spindle 8 — 71

ABS Sensor Harness Retaining Bolt 8 — 71 a Follow the procedure in this section.

Torque Specifications — Motorhome Chassis


Front Spring Hanger Nut-to-Front Spring 246 182 —

Front Spring Hanger Bracket Nut-to-Frame 90 67 —

Front Spring Shackle Bracket Nut-to-Front Spring 125 93 —

Front Spring Shackle Bracket Nut-to-Shackle Bracket Assembly 133 99 —

Shackle Bracket Assembly Nut-to-Frame 90 67 —

Front Spring U-Bolt Nut-to-Axle 353 260 —

Lower Shock Absorber Retaining Nut-to-Front Spring 353 260 —

Upper Shock Absorber Retainer Bolt-to-Upper Shock Absorber Bracket 353 260 —

Upper Shock Absorber Bracket-to-Frame 352 260 —

Upper Stabilizer Bar Link Nut-to-Frame 90 67 —

Stabilizer Bar Clamp-to-Axle Bracket 90 67 —

Stabilizer Bar Axle Bracket-to-Axle 80 60 —

Axle Bumper Assembly-to-Frame 48 36 —

Spindle Steering Drag Link Arm Nut-to-Spindle 575 424 —

Spindle Steering Arm Nut-to-Spindle 575 424 —

Spindle Lock Pin Retaining Nut 81 60 —

Spindle Pin Cap 56 42 —

Tie Rod End Retainer Nut-to-Spindle Steering Arm 89 66 —

Spindle Adapter Plate Retaining Nut-to-Spindle 90 67 —

ABS Sensor Retaining Bolt-to-Spindle 11 — 98

ABS Sensor Harness Retaining Bolt 11 — 98



Manual


Front Suspension

Front Suspension Components — F-250, F-350


1 3B183 Radius Arm Bracket — (LH)

1 3B095 Radius Arm Bracket — (RH)

2 18045 Shock Absorber

3 3B346 Radius Arm — (LH)

3 3405 Radius Arm — (RH)

4 3007 Front Axle I-Beam — (LH)

4 3006 Front Axle I-Beam — (RH)

5 3B404 Upper Ball Joint Adjuster

6 5B316 Lower Spring Seat — (LH)

6 5B307 Lower Spring Seat — (RH)

7 5310 Coil Spring

8 3020 Front Axle Jounce Bumper

9 3C140 Front Stabilizer Bar Link

10 5494 Front Stabilizer Bar



1 5484 Front Stabilizer Bar Insulator

2 3B353 Front Stabilizer Bar Retainer


4 3106 Front Spindle Assy

5 3B008 Tie Rod End

6 3B346 Radius Arm — (LH)

6 3405 Radius Arm — (RH)

7 3B404 Upper Ball Joint Adjuster

8 3007 Front Axle I-Beam — (LH)

8 3006 Front Axle I-Beam — (RH)

9 5B316 Lower Spring Seat —

(with Stabilizer Bar)

10 5A316 Lower Spring Seat — (Without Stabilizer Bar)

11 5414 Lower Spring Insulator

12 5A349 Lower Spring Retainer

13 5310 Coil Spring



1 18035 Upper Shock Bracket

2 3A094 Front Trackbar Bracket

3 3020 Front Axle Jounce Bumper


5 3B353 Stabilizer Bar Retainer

6 5494 Stabilizer Bar

7 5C495 Stabilizer Link Bracket

8 5K483 Stabilizer Bar Link

9 5310 Front Spring Assy

10 5B311 Front Spring Shackle

11 5335 Front Spring Shackle Assy



1 5L302 Front Spring Insulator Sleeve

2 5341 Front Spring Hanger Bracket — (LH)

2 5340 Front Spring Hanger Bracket — (RH)


4 3A094 Front Trackbar Bracket

5 3B239 Front Trackbar Assy

6 5A316 Front Spring Cap

7 5458 Front Spring Spacer Plate

8 N801485-S428 Front Spring U-Bolt

Front Suspension Components — Motorhome Chassis


1 3010 Front Axle Assy

2 3B406 Drag Ling

3 3146 Steering Spindle Drag Link Arm

4 3131 Steering Spindle Arm — (LH)

4 3130 Steering Spindle Arm — (RH)

5 3280 Tie Rod End

6 3145 Front Wheel Spindle Stop

7 3106 Front Wheel Spindle — (LH)

7 3105 Front Wheel Spindle — (RH)

8 3113 Spindle Pin Cap

9 3125 Spindle Pin Seal

10 3123 Spindle Bearing Assy

11 3122 Spindle Pin Locking Bolt

12 3117 Spindle Shim

13 3125 Spindle Pin Seal

14 3122 Spindle Pin Locking Bolt

15 3115 Spindle Pin

Front Suspension Components — Motorhome Chassis


1 5335 Front Spring Shackle Bracket

2 5B311 Front Spring Shackle


4 18035 Front Shock Absorber Bracket


6 5455 Front Spring U-Bolt

7 5486 Stabilizer Bar Mounting Bracket


9 5488 Front Stabilizer Bar-to-Axle Clamp

10 5484 Stabilizer Bar Insulator


12 5L496 Stabilizer Bar Link Bracket

13 5340 Front Spring Hanger Bracket


1999 F-Super Duty 250-550 Workshop Manual


Front Suspension

Refer to Section 204-00.



Manual


Wheel Bearing Adjustment—F-250, F-350, F-450, F-550

CAUTION: Wheel seals on the front axles must be replaced any time the axle lubricants are changed from factory-installed mineral lube to synthetic lube or vice versa.

CAUTION: If bearings are adjusted too tightly, they will overheat and wear rapidly. An adjustment that is excessively loose can cause pounding and contribute to uneven tire wear, steering difficulties and inefficient brakes. Check bearing adjustment at regular inspection intervals. New wheel seals must be installed when the hub is removed. A damaged or worn seal can permit bearing lubricant to reach the brake linings, resulting in ineffective brake operation and necessitating premature replacement of linings. To check the wheel bearing adjustment, raise the front of the vehicle. Grasp the tire at the sides, and alternately push inward and pull outward on the tire. If any looseness is felt, adjust the front wheel bearings as follows.

NOTE: Super Duty F-250, F-350 shown, Super Duty F-450, F-550 similar.

1. Remove the hub cap from the hub.

2. Remove the cotter pin and the castellated nut.

3. While rotating the wheel, tighten the adjusting nut to specification as illustrated to seat the bearings.

4. Back off the adjusting nut until loose.

5. While rotating the wheel, tighten the adjusting nut to specification as illustrated. Torque required to rotate the hub should be 2 Nm (18 lb-in).

6. Install the castellated nut and insert a new cotter pin.

7. Install the hub cap.



Manual


Wheel Bearing Adjustment—Motorhome

CAUTION: Wheel seals on the front axles must be replaced any time the axle lubricants are changed from factory-installed mineral lube to synthetic lube or vice versa.

CAUTION: If bearings are adjusted too tightly, they will overheat and wear rapidly. An adjustment that is excessively loose can cause pounding and contribute to uneven tire wear, steering difficulties and inefficient brakes. Check bearing adjustment at regular inspection intervals. New wheel seals must be installed when the hub is removed. A damaged or worn seal can permit bearing lubricant to reach the brake linings, resulting in ineffective brake operation and necessitating premature replacement of linings. To check the wheel bearing adjustment, raise the front of the vehicle. Grasp the tire at the sides, and alternately push inward and pull outward on the tire. If any looseness is felt, adjust the front wheel bearings as follows.

1. Remove the hub cap and gasket from the hub.

2. Remove the cotter pin.

3. While rotating the wheel, tighten the adjusting nut to specification as illustrated to seat the bearings.

4. Back off the adjusting nut until loose.

5. Finger-tighten the adjusting nut. Final bearing adjustment end play must be within the specification as illustrated. The final adjustment must not result in a preloaded bearing.

6. If the cotter pin hole lines up with a slot in the nut, insert and secure the new cotter pin. If it does not, advance the adjusting nut to align a slot with the first available cotter pin hole. Insert and secure a new cotter pin.

7. Install the gasket and hub cap.



Manual

REMOVAL AND INSTALLATION Procedure revision date: 01/26/2000

Wheel Hub and Bearing—F-250, F-350

Removal


2. Remove the front wheel and tire assemblies; for additional information, refer to Section 204-04.

3. Remove the front disc brake caliper and rotor, and position the caliper out of the way; for additional information, refer to Section 206-03.

4. Remove the hub cap from the hub assembly.

5. Remove the cotter pin, adjusting nut and flatwasher.

6. NOTE: Inspect the condition of the spindle and nut threads to ensure a free turning nut when reassembling.

Remove the outer bearing cone and roller assembly, and pull the hub assembly from the spindle.

7. Using care not to damage the bearing cage, use a suitable slide hammer and bearing seal remover to remove the inner bearing cone and bearing seal.

Installation

1. CAUTION: Do not spin the bearing dry with compressed air.

NOTE: Remove all traces of lubricant from the bearings, hub and axle spindle. Inspect bearings and bearing cups for pitting, spalling or unusual wear. If either bearings or bearing cups are worn or damaged, replace both bearings and bearing cups.

NOTE: It is recommended that bearings and bearing cups be replaced in sets. If cups are worn or damaged, install the inner and outer bearing cups in the hub with an appropriate

bearing cup driver tool. Check for proper seating of new bearing cups by trying to insert a 0.38-mm (0.0015-inch) feeler gauge between the bottom face of the cup and wheel hub seat. You should not be able to insert the feeler gauge.

Remove all burrs, nicks or scratches from the shoulder of the spindle and seal bore in the hub with emery cloth.

2. Pack the inside of the hub with lithium-base wheel bearing grease such as Motorcraft Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B. Fill the hub until the grease is flush with the inside diameters of both bearing cups.

3. Pack the bearing cone and roller assemblies with wheel bearing grease. Use a bearing packer for this operation. If a packer is not available, work as much lubricant as possible between the rollers and cages.

4. CAUTION: Keep the hub centered on the spindle to prevent damage to the grease seal or spindle threads.

Place the inner bearing cone and roller assembly in the inner cup and install the wheel bearing hub seal, using a suitable seal replacer. Make sure seal is fully seated and lubricated.

5. Install the hub assembly.

6. Install the outer bearing cone and roller assembly and the flatwasher on the spindle and install the adjusting nut; refer to Wheel Bearing Adjustment—F-250, F-350, F-450, F-550 in this section for final bearing adjustment. Install a new cotter pin.

7. Install the hub cap.

8. Install the front disc brake caliper and rotor; for additional information, refer to Section 206-03.

9. Install the front wheel and tire assemblies; for additional information, refer to Section 204-04.





Wheel Hub and Bearing—F-450, F-550

Removal and Installation

1. Remove the wheel and tire assembly. For additional information, refer to Section 204-04.

2. Disconnect the wheel speed sensor electrical connector.

3. Detach the sensor harness from the brake hose.

4. Remove the bolts and position the caliper, pads and anchor plate aside.

5. Remove the eight nuts, the hub extender and the brake disc.

6. Remove the bolt.

7. Remove the nuts and the hub and bearing.

8. Remove the shield.

9. Remove the bolt and the sensor.

10. Position the hub and bearing in a vise with protective caps, and remove the studs using two mounting nuts.

11. Remove and discard the O-ring.

12. CAUTION: Make sure that the wheel hub and brake disc mounting surfaces are clean.

To install, reverse the removal procedure.




Wheel Hub and Bearing—Motorhome

Removal



3. Remove the front disc brake caliper and position out of the way; for additional information, refer to Section 206-03.

4. Remove the hub cap and gasket from the hub and rotor assembly.

5. Remove the cotter pin, adjusting nut and flatwasher.

6. NOTE: Inspect the condition of the spindle and nut threads to ensure a free turning nut when reassembling.

Remove the outer bearing cone and roller assembly.

7. Pull the hub and rotor assembly from the spindle.

8. Using care not to damage the bearing cage, use a suitable slide hammer and bearing seal remover to remove the inner bearing cone and bearing seal.

Installation

1. CAUTION: Do not spin the bearing dry with compressed air.

NOTE: Remove all traces of old lubricant from the bearings, hub and axle spindle. Inspect bearings and bearing cups for pitting, spalling or unusual wear. If either bearings or bearing cups are worn or damaged, replace both bearings and bearing cups.

NOTE: It is recommended that bearings and bearing cups be replaced in sets. If cups are worn or damaged, install the inner and outer bearing cups in the hub with an appropriate bearing cup driver tool. Check for proper seating of new bearing cups by trying to insert a 0.38-mm (0.0015-inch) feeler gauge between the bottom face of the cup and wheel hub seat. You should not be able to insert the feeler gauge.

Remove all burrs, nicks or scratches from the shoulder of the spindle and seal bore in the hub with emery cloth.

2. Pack the inside of the hub with lithium-base wheel bearing grease such as Motorcraft Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B. Fill the hub until the grease is flush with the inside diameters of both bearing cups.

3. Pack the bearing cone and roller assemblies with wheel bearing grease. Use a bearing packer for this operation. If a packer is not available, work as much lubricant as possible between the rollers and cages.

4. CAUTION: Keep the hub centered on the spindle to prevent damage to the grease seal or spindle threads.

Place the inner bearing cone and roller assembly in the inner cup and install the wheel bearing hub seal, using a suitable seal replacer. Make sure seal is fully seated and lubricated.

5. Install the rotor and hub assembly.

6. Install the outer bearing cone and roller assembly and the flatwasher on the spindle.

7. Install the adjusting nut, refer to Wheel Bearing Adjustment—Motorhome in this section for final bearing adjustment. Install a new cotter pin.

8. Install a new gasket and the hub cap.

9. Install the front disc brake caliper and rotor; for additional information, refer to Section 206-03.

10. Install the front wheel and tire assemblies; for additional information, refer to Section 204-04.





Wheel Studs—F-250, F-350

Removal

1. Raise and support the vehicle. For additional information, refer to Section 100-02.


3. Remove the disc brake caliper and the disc brake rotor. For additional information, refer to Section 206-04.

4. Using a suitable press, remove the lug bolt from the disc brake rotor and discard.

Installation

1. Using a suitable press, install the new lug bolt aligning the serrations in the disc brake rotor flange made by the original lug bolt.

2. Install the disc brake rotor and disc brake caliper. For additional information, refer to Section 206-04.

3. Install the wheel and tire assembly. For additional information, refer to Section 204-04.

4. Lower the vehicle. For additional information, refer to Section 100-02.



Manual


Wheel Studs—F-450, F-550 and Motorhome

Special Tool(s)

C-Frame and Clamp Assembly Tool 211-023 (T74P-3044-A1)

Removal



3. Using the C-Frame and Clamp Assembly Tool, remove the lug bolt from the wheel adapter and discard.

Installation

1. Install the new lug bolt aligning the serrations in the wheel adapter flange made by the original lug bolt.

• Place four flatwashers over the outside end of the lug bolt and thread a standard lug nut with the flat side against the washers.

• Tighten the lug nut until the lug bolt head seats against the back side of the wheel adapter flange.

2. Remove the lug nut and flatwashers.






Arm—Radius, F-250, F-350, Excursion


For additional information, refer to Axle—F-250, F-350 in this section.



Manual


Bar—Trackbar, F-450, F-550

Removal

1. CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. They must be replaced with the same part number or an equivalent part if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during re-assembly to ensure proper retention of these parts.


2. NOTE: To prevent the front suspension from shifting when the trackbar is removed, the front suspension must be supporting the vehicle weight.

Load the front suspension with the vehicle weight.

1. Position the jack stand under the front axle assembly.

2. Lower the vehicle until the front suspension is supporting the vehicle weight.

3. Disconnect the trackbar from the upper mounting bracket. 1. Remove the nut and bolt.

2. Remove the trackbar from the bracket.

4. Remove the trackbar from the lower mounting bracket. 1. Remove the nut and bolt.

2. Remove the trackbar.

Installation

1. Using new fasteners, follow the removal procedure in reverse order.




Bar and Link—F-250, F-350

Removal



2. Remove the stabilizer bar retainer brackets. 1. Remove the bolts.

2. Remove the retainer brackets.

3. Remove the stabilizer bar. 1. Remove the lower stabilizer bar link nuts, washers and bolts.

2. Remove the stabilizer bar.

3. Remove the upper stabilizer bar link nuts and bolts, and remove the links.

Installation




Manual


Bar and Link—F-450, F-550

Removal



2. Remove the stabilizer bar link. 1. Remove the nut.

2. Remove the nut, washer and bolt.

3. Remove the stabilizer bar link.

• Repeat on the other side.

3. Remove the stabilizer bar. 1. Remove the retainer bracket bolts.

2. Remove the retainer brackets.


Installation




Manual


Bar and Link—Motorhome

Removal



2. Remove the stabilizer bar links. 1. Remove the upper stabilizer bar link nuts, washers, bolts and bracket.

2. Remove the lower stabilizer bar link nuts, washers, bolts and bracket.


4. Repeat on the other side.

3. Remove the front stabilizer bar. 1. Remove the retaining nuts and bolts. Repeat on the other side.

2. Remove the retaining clamp. Repeat on the other side.


Installation




Manual


Bushing—Spindle, Motorhome

Removal

1. Remove spindle; for additional information, refer to Spindle—Motorhome.

2. On a spindle with bronze or low friction (garlock) bushings, press the bushing out of the spindle with a tool that is slightly smaller then the spindle bore.

3. Clean the spindle bores thoroughly. Make sure lubricating holes are not plugged.

Installation

1. Position the new bushing in the spindle bore. For spindles with bronze bushings, position the lubricating hole in line with the lubricating fitting, and the open end of the oil groove toward the axle. Press the bushing into the spindle with a driver that pilots in the bushing.

2. Press the bushing until there is 3.4-4.1 mm (0.133-0.161 inch) between the bottom of the bushing and the bottom of the top bore.

3. Turn the spindle over and install the remaining bushing in the same manner.

4. Clean the bushing and coat the bushing and pin with lubricant prior to assembly.

5. Install spindle; for additional information, refer to Spindle—Motorhome in this section.



Manual


Spindle—F-250, F-350

Special Tool(s)

Pitman Arm Puller 211-003 (T64P-3590-F)

Removal



2. Remove the wheel and tire assembly; for additional information, refer to Section 204-04.

3. Remove the disc brake caliper and the front disc brake hub and rotor; for additional information, refer to Section 206-03.

4. Remove the front disc brake rotor shield.

5. If equipped, remove the ABS sensor retaining bolt, ABS sensor harness retaining bolt and the ABS sensor. Position out of the way.

6. Disconnect the tie rod end. 1. Remove and discard the cotter pin.

2. Remove the castellated nut.

3. Using the Pitman Arm Puller, remove the tie rod end.

7. Remove the pinch bolt.

8. Remove the camber adjuster.

9. CAUTION: To prevent damage to the ball joint seal and the ball joint socket, do not use a pickle fork-type remover to loosen the ball joints.

Remove the front wheel spindle.

1. Remove and discard the cotter pin.

2. Loosen, but do not remove, the castellated nut.

3. Strike the lower end of the front axle to loosen the ball joint.

4. Remove the castellated nut and the front wheel spindle.

Installation

1. NOTE: Tighten the ball joint nut further, if necessary, in order to insert a new cotter pin.

Using new fasteners, follow the removal procedure in reverse order.

2. Check the front end alignment; for additional information, refer to Section 204-00.



Manual


Spindle—F-450, F-550

Special Tool(s)

Pitman Arm Puller 211-003 (T64P-3590-F) or Equivalent

Removal


NOTE: Right side shown, left side similar.



3. Remove the front disc brake caliper and the front disc brake rotor; for additional information, refer to Section 206-03.

4. Remove and discard the cotter pin, and remove the castellated nut.



7. Remove and discard the cotter pin.

8. Remove the upper ball joint castellated nut.

9. Loosen, but do not remove, the lower ball joint retaining nut.


Strike the lower and upper end of the axle to loosen ball joints and the camber adjuster.

11. Using the Pitman Arm Puller, remove the camber adjuster sleeve.

12. Remove the lower ball joint retaining nut and front wheel spindle.

Installation

1. Position the spindle into the axle. • Apply Threadlock® and Sealer EOAZ-19554-AA or equivalent meeting Ford

Specification WSK-M2G315-A5 (Type II).

2. Install the camber adjuster sleeve.

3. Install the new nut and tighten to initial torque.

4. NOTE: Tighten the upper ball joint nut further, if necessary, in order to insert the new cotter pin.

Install a new castellated nut and a new cotter pin.

5. Tighten the nut to final torque.

6. If equipped, install the ABS sensor, ABS sensor retaining bolt and the ABS sensor harness retaining bolt.

7. Using a new castellated nut and a new cotter pin, install the tie rod end.

8. Install the front disc brake rotor and the front disc brake caliper; for additional information, refer to Section 206-03.

9. Install the wheel and tire assembly, for additional information, refer to Section 204-04.






Spindle—Motorhome

Special Tool(s)


Removal


NOTE: Right side shown, left side similar.



3. Remove the front disc brake caliper and the front disc brake hub and rotor; for additional information, refer to Section 206-03.

4. Remove and discard the cotter pin and remove the castellated nut.



7. Remove the six torque plate retaining nuts and bolts, and remove the torque plate.

8. Remove and discard the cotter pin and remove the castellated nut. Disconnect the spindle arm from the spindle.

9. Remove the upper and lower spindle caps and spindle seals.

10. Remove the upper and lower lock pin retaining nuts.

11. Using a bronze drift, drive out the lock pins.

12. Using a bronze drift, drive out the spindle pin.

13. Remove the spindle, spindle bearing and the spindle shim(s) from the axle assembly.

Installation

1. NOTE: Pack the spindle bearing and coat all mating surfaces of spindle and axle parts with Motorcraft Premium Long Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B prior to assembly.

NOTE: The spindle bearing must be installed with the retainer lip facing down.

NOTE: Use shims as required to maintain a 0.076-0.254-mm (0.003-0.010-inch) axle-to-spindle clearance.

Position the spindle, spindle bearing and the spindle shim(s) on the front axle assembly.

2. Insert the spindle pin into the axle until the notches in the spindle pin and the holes in the axle are in line.

3. NOTE: Do not install both lock pins from the same side of axle.

Install the lower (longer) lock pin first, and seat using a bronze drift.

4. Install the upper (shorter) lock pin, and seat using a bronze drift.

5. Install new lock pin retaining nuts.

6. Install the upper and lower spindle seals and caps.

7. Align the key in the spindle arm with the key way slot in the spindle, and insert the spindle arm.

8. Install a new castellated nut and a new cotter pin.

9. Using new fasteners, install the torque plate.

10. If equipped, install the ABS sensor, ABS sensor retaining bolt and the ABS sensor harness retaining bolt.

11. Install the tie rod end using a new castellated nut and a new cotter pin.

12. Install the front disc brake hub and rotor and the front disc brake caliper; for additional information, refer to Section 206-03.

13. Install the wheel and tire assembly; for additional information, refer to Section 204-04.





Manual


Shock Absorber—F-250, F-350

Removal

WARNING: All vehicles are equipped with gas-pressurized shock absorbers which will extend unassisted. Do not apply heat or flame to the shock absorbers during removal or component servicing.

CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. They must be replaced with the same part number or an equivalent part if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during re-assembly to ensure proper retention of these parts.

1. Raise the hood and remove the upper shock absorber retaining nut and upper shock absorber insulator.

2. Raise and support the vehicle: for additional information, refer to Section 100-02.

3. Remove the lower shock absorber retaining nut and remove the shock absorber.

Installation





Shock Absorber—F-450, F-550

Removal





3. Using a suitable jack, support the front axle assembly.

4. Remove the upper shock absorber retaining bolt.

5. Remove the lower shock absorber retaining nut and bolt. Remove the shock absorber.

Installation





Shock Absorber—Motorhome

Removal





3. Remove the upper shock absorber retaining nut, washers and bolt.

4. Remove the lower shock absorber retaining nut, washers and bolt. Remove the shock absorber.

Installation




Manual


Spring—F-250, F-350

Removal

CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. Install new parts with the same part number or an equivalent part if installation is necessary. Do not install a part of lesser quality or substitute design. Torque values must be used as specified during reassembly to ensure correct retention of these parts.



3. Remove the nut and detach the shock from the mounting stud.

4. Remove the upper spring retainer.

5. Lower the front axle until the spring is free of the upper spring seat.

6. Using an extension through the top of the spring, remove the lower spring retainer.

7. Remove the front spring.

Installation

1. Using new fasteners, reverse the removal procedure.




Spring—F-450, F-550

Removal






4. Remove the front shock absorber lower mounting nut and bolt.

5. NOTE: The front spring hanger has seven flange nuts located inside the frame rail and must be positioned in the same location for installation.

Remove the front spring hanger and hanger bracket.

1. Remove the two spring hanger bracket bolts and flange nuts.

2. Remove the five spring hanger bolts.

6. Remove and discard the nut and bolt that retain the front spring to the spring shackle.

7. If equipped, remove the spring insulator and hold for reinstallation.

8. Remove and discard the four U-bolt nuts.

9. Remove and discard the two U-bolts, and remove the spring spacer and the spring.

10. Remove the nut and bolt from the front spring hanger, and remove the hanger and hanger bracket.

Installation

1. Position the spring in the front spring hanger and install a new bolt from inside to outside. Position the spring hanger bracket to the spring hanger, and install a new nut hand-tight.

2. Position the spring on the axle.

3. Install a new bolt and nut to retain the front spring to the spring shackle hand-tight.

4. Using new fasteners, install the front spring hanger and hanger bracket. 1. Position the spring, spring hanger and spring hanger bracket. Line up the flange

nuts inside the frame rail, and start the spring hanger bracket retaining bolts by hand, using caution not to cross thread the bolts.

2. Position the flange nuts inside the frame rail and start the spring hanger retainer bolts by hand, using caution not to cross-thread the bolts.

3. Tighten the bolts.

5. Position the spring spacer and two new U-bolts.

6. Install four new U-bolt retaining nuts.

7. Install a new front shock absorber lower bolt and nut.

8. If equipped, install the spring insulator.


10. Remove the jack stands.


12. With the weight of the vehicle on the wheels, tighten the front hanger bolt and nut.

13. With the weight of the vehicle on the wheels, tighten the shackle bolt and nut.




Spring—Motorhome

Removal





3. Using suitable jack stands, support the front axle assembly.

4. Remove the front shock absorber lower mounting nut, washers and bolt.

5. Remove the nut and bolt that retain the spring to the front spring hanger.

6. Remove the nut and bolt that retain the spring to the spring shackle.

7. If equipped, remove the spring insulator and hold for reinstallation.

8. Remove the four U-bolt nuts, washers and the two U-bolts. Remove the spring.

Installation



Manual


Axle—F-250, F-350

Special Tool(s)


Removal




3. Remove the front disc brake caliper, front disc brake hub and rotor and front disc brake rotor shield. For additional information, refer to Section 206-03.

4. If equipped, remove the front disc brake ABS sensor retainer bolt and the ABS sensor harness bracket bolt from the front wheel spindle. Position the ABS sensor out of the way.

5. Remove the cotter pin and the castellated nut from the tie rod end. Discard the cotter pin.


7. Remove the cotter pin and the lower ball joint castellated nut. Discard the cotter pin.

8. Remove the pinch bolt and the camber adjuster from the upper ball joint.


Remove the front wheel spindle.

1. Strike the lower end of the axle to loosen the ball joint.

2. Remove the front wheel spindle.

10. Using a suitable jack, support the front axle.

11. Remove the front coil spring. For additional information, refer to Spring—F-250, F-350 in this section.

12. Remove the lower spring insulator.

13. Remove the lower spring seat.

14. Remove the radius arm-to-axle bolt and nut.

15. Remove the radius arm-to-frame bracket pivot bolt and nut. Remove the radius arm.

16. NOTE: In order to obtain clearance for the pivot bolt removal when servicing the RH front axle, it may be necessary to raise the side of the vehicle to relieve the weight on the suspension.

Remove the pivot nut and bolt, and remove the axle.

Installation

1. Inspect the pivot bushing for wear or damage. Replace as necessary.

2. Position the front axle into the pivot bracket and install a new pivot bolt and nut hand-tight.

3. Inspect the radius arm pivot bushing for wear or damage. Replace as necessary.

4. Install a new radius arm-to-axle bolt and nut hand-tight.

5. Install a new radius arm-to-frame bracket pivot bolt and nut. Tight to specification.

6. Tighten the radius arm-to-axle bolt and nut to specification.

7. Install the lower spring seat.

8. Install the lower spring insulator.

9. Install the front coil spring. For additional information, refer to Spring—F-250, F-350 in this section.

10. NOTE: Tighten the ball joint nut further, if necessary, in order to insert the new cotter pin.

Using new fasteners, install the front wheel spindle in the front axle.

1. Position the front wheel spindle in the front axle.

2. Install the ball joint nut and tighten to specification.

3. Install the new cotter pin.

11. Install the camber adjuster and a new pinch bolt.

12. Install the front disc brake rotor shield, front disc brake hub and rotor and the front disc brake caliper. For additional information, refer to Section 206-03.

13. If equipped, install the front disc brake ABS sensor, retainer bolt and the ABS sensor harness bracket bolt.

14. Install the tie rod end in the front wheel spindle using a new nut and a new cotter pin.

15. Install the tire and wheel assembly. For additional information, refer to Section 204-04.

16. Lower the vehicle and with the vehicle weight on the suspension, tighten the axle pivot bolt and nut to specification.

17. Perform front end alignment. For additional information, refer to Section 204-00.



Manual


Axle—F-450, F-550

Special Tool(s)


Removal



2. Remove the front wheels and tire assemblies. For additional information, refer to Section 204-04.

3. Remove the front disc brake calipers and position out of the way. For additional information, refer to Section 206-03.

4. If equipped, disconnect the front disc brake ABS sensor harness connectors and position harness out of the way. For additional information, refer to Section 206-09A or Section 206-09B.

5. Using a suitable jack, equipped with safety chains, support the front axle.

6. Remove the front shock absorbers. For additional information, refer to Shock Absorber—F-450, F-550 in this section.

7. Remove and discard the bolts from the stabilizer bar mounting brackets to axle, and position out of the way.

8. Disconnect the trackbar from the upper mounting bracket. 1. Remove and discard the nut and bolt.


9. Remove the trackbar from the lower mounting bracket. 1. Remove and discard the nut and bolt.


10. Remove the cotter pin and the castellated nut from the drag link to pitman arm. Discard the cotter pin.

11. Using the Pitman Arm Puller, remove the drag link to pitman arm, and secure the drag link to the tie rod.

12. Remove and discard the nut and bolt from the steering damper-to-axle mounting bracket, and secure the steering damper to the tie rod.

13. Remove the steering linkage assembly. 1. Remove both cotter pins from the outer tie rod ends and discard.

2. Remove both castellated nuts from the outer tie rod ends.

3. Remove the steering linkage assembly.

14. Remove and discard the U-bolt retaining nuts and the U-bolts. • Remove the spring spacer plates. • Lower the jack, and remove the axle assembly.

Installation


2. Perform front end alignment. For additional information, refer to Section 204-00.



Manual


Axle—Motorhome

Special Tool(s)


Removal




3. Remove the front disc brake calipers and position out of the way; for additional information, refer to Section 206-03.

4. If equipped, remove the ABS sensor retaining bolt and ABS sensor harness retaining bolt and position out of the way.

5. Using a suitable jack equipped with safety chains, support the front axle.

6. Remove the front shock absorbers; for additional information, refer to Shock Absorber—Motorhome in this section.

7. Remove the spindles; for additional information, refer to Spindle—Motorhome in this section.

8. Remove the sway bar; for additional information, refer to Bar and Link—Motorhome in this section.

9. Remove the front spring U-bolt retaining nuts and remove the U-bolts and upper spring spacer plates.

10. Lower the jack and remove the axle assembly.

Installation


2. Perform front end alignment; for additional information, refer to Section 204-00.

SECTION 204-01B:

Front Suspension — 4x4

SPECIFICATIONS


Front Suspension


Front Suspension

GENERAL PROCEDURES

Ride Height

Vacuum Leak Test—Wheel End

REMOVAL AND INSTALLATION

Wheel Hub

Wheel Studs

Bar—Stabilizer

Bar—Track

Bar—Link Stabilizer

Bushing—Stabilizer Bar

Wheel Knuckle

Ball Joint—Upper

Ball Joint—Lower

Shock Absorber

Spring—Leaf

Spring—Shackle

Spring—Hanger

Vacuum Valve

SECTION 204-01B: Front Suspension —

4x4 1999 F-Super Duty 250-550 Workshop Manual



Item Specification

High Temperature 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590-A ESA-M1C198-A



Front Spring-to-Axle U-Bolts 133 99 —

Front Spring-to-Spring Hanger Nut 350 259 —

Front Spring-to-Shackle Nut 250 185 —

Spring Hanger-to-Frame Bolts 103 76 —

Spring Shackle-to-Frame Nut 250 185 —

Stabilizer Bar-to-Front Spring Spacer Bolts (LH Side Only) 47 35 —

Stabilizer Bar-to-Axle Assembly Bracket Bolts (RH Side Only) 47 35 —

Stabilizer Bar-to-Link Nut 80 60 —

Stabilizer Bar Link-to-Bracket Nut 80 60 —

Front Shock-to-Upper Shock Bracket Nut 103 76 —

Front Shock-to-Front Spring Spacer Nut 103 76 —

Jounce Bumper-to-Frame Bolts 40 30 —

Shock Absorber Upper Mounting Bracket-to-Frame Bolts 103 76 —

Trackbar-to-Upper Mounting Bracket Nut 174 129 —

Trackbar-to-Lower Mounting Bracket Nut 174 129 —

Shackle Bracket Assembly-to-Frame Bolts 87 65 —

Stabilizer Bar Bracket-to-Frame Bolts 47 35 —

Front Driveshaft-to-Pinion Flange Bolts 102 76 —

Front Hub and Bearing-to-Knuckle Nuts 74 55 —

Tie Rod End-to-Front Knuckle Nut 70 52 —

Vacuum Valve Mounting Bolts 11 — 98

Lower Ball Joint Nut 136 101 —

Upper Ball Joint Nut 136 101 —



Manual


Front Suspension

Front Suspension with Dana Model 50 and Dana Model 60 Front Drive Axles


1 N807147-S426 Bolt, M16 x 2 x 143 x 10.9

2 5335 Bracket Assy

3 N811403-S426 Bolt, M12 x 1.75 x 40 x 10.9

4 N800237-S426 Flag Nut, M1.6 x 2 x 20 x 10

5 5B311 Spring Shackle

6 N806085-S426 Nut and Washer, M12 x 1.75

7 18045 Shock Assy

8 18035 Upper Shock Bracket

9 N800937-S426 Flag Nut

10 N805845-S426 Bolt, M12 x 1.75 x 80 x 10.9

11 N811631-S426 Nut, M12 x 1.75 x 13 x 10

12 — Tow Hook

13 N807659-S426 Flag Nut

14 5341 Spring Hanger

15 W704660-S426 Bolt, M18 x 2.5 x 136 x 10.9

16 5310 Spring Assy

17 N801485-S428 U-Bolt, M14 x 2 x 92 x 201

18 5458 Spacer

19 N805480-S426 Flag Nut

20 3A094 Trackbar Bracket

21 N803960-S426 Bolt, M14 x 2 x 90 x 10.9

22 3B239 Trackbar

23 5A316 Spring Cap

24 N605803-S426 Bolt, M10 x 1.5 x 40 x 9.8

25 3B353 Stabilizer Bar Retainer Bracket

26 — Drive Axle, Dana Model 50

27 — Drive Axle, Dana Model 60

28 N807164-S426 Flag Nut

29 N801673-S426 U-Nut

30 5484 Stabilizer Bar Insulator



Manual


Front Suspension

Refer to Section 204-00 or Section 100-04.




Ride Height

For additional information, refer to Section 204-00.




Vacuum Leak Test—Wheel End

Special Tool(s)

Vacuum Tester 416-D002 (D95L-7559-A) or Equivalent

1. NOTE: Whenever the front wheel hub, axle shaft or the hub lock is removed and installed, the front wheel-end assemblies must be leak-checked to ensure that the sealing

surfaces are intact. Failure to do so can cause the loss of four-wheel drive operation and contamination of the vacuum system.

Disconnect the wheel-end vacuum hose.

2. Connect the hand vacuum pump (part of Vacuum Tester) to the vacuum fitting on the wheel knuckle.

3. NOTE: The wheel-end assembly must not leak more than 0.50 in-Hg in 30 seconds. If the wheel-end leak rate exceeds the specification, refer to Section 308-07A under Diagnosis and Testing.

Apply 15 in-Hg of vacuum to the wheel-end assembly and observe the reading for 30 seconds.

4. Repeat the leak testing procedure for the opposite wheel-end.



Manual


Wheel Hub

Removal

All vehicles

1. Remove the front brake disc. For additional information, refer to Section 206-03.

2. Remove the hub lock. 1. Remove the retainer ring.

2. Pull outward and remove the hub lock.

3. Remove the axle shaft thrust washers. 1. Remove the snap ring.

2. Remove the three thrust washers.

Vehicles equipped with ABS

4. CAUTION: Do not remove the ABS sensor from the bearing.

Disconnect the ABS wheel sensor harness.

1. Disconnect the connector.

2. Disconnect the harness routing clips.

All vehicles

5. NOTE: The wheel hub and bearing is a slip fit design and should not require a puller to remove it.

Remove the wheel hub and bearing.

1. Remove the four lock nuts.

2. Remove the wheel hub and bearing.

6. Remove the brake disc shield.

Vehicles with ABS

7. Remove the bolt and the ABS sensor.

All vehicles

8. NOTE: Position the hub in a soft-jawed vise.

Install two nuts on the studs and use the inner nut to remove the studs.

9. Remove and discard the O-ring.

Installation

All vehicles

1. NOTE: Any time the wheel hub is removed for any reason, a new O-ring seal must be installed. Failure to do so can cause a vacuum leak and loss of four wheel drive operations.

Install a new O-ring.

2. NOTE: Position the hub in a soft-jawed vise.

Install two nuts on the studs and use the outer nut to install the studs.

Vehicles equipped with ABS

3. Position the ABS sensor and install the bolt.

All vehicles

4. Position the brake disc shield.

5. NOTE: Apply a coat of Ford High Temperature 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590-A meeting Ford specification ESA-M1C198-A to the O-ring area of the wheel hub and bearing before installing the hub and bearing.

Install the wheel hub and bearing.

1. Position the wheel hub and bearing.

2. Install the four lock nuts.

Vehicle equipped with ABS

6. NOTE: The following step applies only to vehicles equipped with ABS.

Connect the ABS sensor harness.

1. Position the ABS sensor harness and install the routing clips.

2. Connect the harness connector.

All vehicles

7. CAUTION: The non-metallic thrust washer must be installed between the two metal thrust washers. Failure to do so will cause severe wear to the non-metallic thrust washer, allowing the axle shaft to travel further in and out during torque thrust causing damage to the wheel hub and bearing, the axle shaft end seal and the axle shaft.

Install the snap ring.

1. Position the three thrust washers onto the axle shaft.

2. Install the snap ring.

8. NOTE: Any time the hub lock is removed, a new O-ring seal must be installed. Failure to do so can cause a vacuum leak and loss of four wheel drive functions.

Install a new O-ring.

9. Install the hub lock. 1. Position the hub lock.

2. Install the retainer ring.

10. Install the brake disc. For additional information, refer to Section 206-03.

11. Perform the wheel-end vacuum leak test. For additional information, refer to Section 308-07A.



Manual


Wheel Studs

For additional information, refer to Section 204-01A.




Bar—Stabilizer


1. NOTE: Both the left and right sides of the stabilizer bar are removed and installed the same way. Only the left side is shown.

Remove the nut, washer, and bolt, and disconnect the stabilizer bar link.

2. Remove the bolts and the stabilizer bar.

3. To install, reverse the removal procedure.




Bar—Track

Removal

1. Raise and support the vehicle; refer to Section 100-02.

2. NOTE: To prevent the front suspension from shifting when the trackbar is removed, the front suspension must be supporting the vehicle's weight.

Load the front suspension with the vehicle's weight.

1. Position jack stands under the front axle housing.

2. Lower the vehicle until the front suspension is supporting the vehicle's weight.

3. Disconnect the trackbar from the upper mounting bracket. 1. Remove the nut and bolt.


4. Remove the trackbar from the lower mounting bracket. 1. Remove the nut and bolt.


Installation

1. Follow the removal procedure in reverse order.




Bar—Link Stabilizer

Removal

1. Disconnect the stabilizer bar link from the stabilizer bar. 1. Remove the nut and washer.

2. Remove the bolt.

2. NOTE: The following step is for the left hand stabilizer bar link only.

Remove the stabilizer bar link.

1. Remove the nut.


3. NOTE: The following step is for the right hand stabilizer bar link only.

Remove the stabilizer bar link.

1. Remove the nut and washer.

2. Remove the bolt and the stabilizer bar link.

4. Remove the stabilizer bar link bracket. 1. Remove the three bolts and flag nuts.

2. Remove the stabilizer bar link bracket.

Installation




Manual


Wheel Knuckle

Special Tool(s)


Driver 205-199 (T83T-3132-A1)

Knuckle Seal Installer 205-429

Removal



3. Remove the front brake disc. For additional information, refer to Section 206-03.

4. Remove the wheel hub and bearing. For additional information, refer to Wheel Hub in this section.

5. Using a drift, drive the axle shaft main seal out of the wheel knuckle.

6. Remove the axle shaft and main seal.

7. Remove the tie-rod end castellated nut. 1. Remove the cotter pin.

2. Remove the castellated nut.

8. Using the special tool, disconnect the tie-rod end from the wheel knuckle.

9. Remove the upper ball joint castellated nut and the insert. 1. Remove the cotter pin.

2. Remove the nut.

3. Remove the insert.

10. Remove the wheel knuckle. 1. Remove the lower ball joint nut.

2. Remove the knuckle.

11. Clean and inspect the wheel knuckle ball joint bores.

Installation

1. Position the wheel knuckle onto the axle housing.

2. Install the nut onto the lower ball joint. Do not tighten the nut at this time.

3. Install the insert and the castellated nut onto the upper ball joint. Do not tighten the nut at this time.

4. Tighten the lower ball joint retaining nut. Pre-tighten the nut to 47 Nm (35 lb-ft).

5. NOTE: Do not loosen the castellated nut to install the cotter pin.

Install the cotter pin into the upper ball joint.

1. Tighten the upper ball joint castellated nut.

2. Install the cotter pin. If necessary, tighten the castellated nut until the cotter pin can be installed.

6. Tighten the lower ball joint nut to 204 Nm (150 lb-ft).

7. Install the tie-rod end onto the wheel knuckle. 1. Position the tie-rod end into the wheel knuckle.

2. Install and tighten the castellated nut.

3. Install the cotter pin.

8. Install the new main seal onto the axle shaft. 1. Position the main seal onto the axle shaft.

2. Using the special tools and a hammer, seat the main seal onto the axle shaft.

9. Position the axle shaft into the axle housing.

10. Using the special tools and a hammer, install the main seal into the wheel knuckle.

11. Install the wheel hub and bearing. For additional information, refer to Wheel Hub in this section.

12. Install the front brake disc. For additional information, refer to Section 206-03.




Manual


Ball Joint—Upper

Removal

1. Remove the wheel knuckle. For additional information, refer to Wheel Knuckle in this section.

2. Place the wheel knuckle into a suitable vise.

3. NOTE: Always remove the lower ball joint first.

Remove the lower ball joint. For additional information, refer to Ball Joint—Lower in this section.

4. Using a suitable ball joint press, remove the ball joint.

Installation

1. Clean the wheel knuckle ball joint bores.

2. Using a suitable ball joint press, install the ball joint.

3. Install the lower ball joint. For additional information, refer to Ball Joint—Lower in this section.

4. Install the wheel knuckle. For additional information, refer to Wheel Knuckle in this section.



Manual


Ball Joint—Lower

Removal

1. Remove the wheel knuckle. For additional information, refer to Wheel Knuckle in this section.

2. Place the wheel knuckle into a suitable vise.

3. Remove the snap ring.

4. Using a suitable ball joint press, remove the ball joint.

Installation

1. Clean the wheel knuckle ball joint bore.

2. Using a suitable ball joint press, install the ball joint.

3. Install the snap ring.

4. Install the wheel knuckle. For additional information, refer to Wheel Knuckle in this section.



Manual


Shock Absorber




3. NOTE: Both the left and right side shock absorbers are removed and installed the same way. Only the left side is shown.

Disconnect the shock absorber lower mount.

1. Remove the nut.

2. Remove the bolt.

4. Disconnect the shock absorber upper mount. 1. Remove the nut.

2. Pull the shock absorber away from the mounting stud.



Manual


Spring—Leaf

Removal


2. Position jack stands under the axle housing.

3. NOTE: The following step is for the left-hand shock only.

Remove the shock.

1. Remove the nut and bolt.

2. Remove the shock from the front spring cap.

4. CAUTION: Never reuse U-bolts. The U-bolts are a torque-to-yield design and cannot be retightened. Failure to use a new U-bolt can result in loose or broken springs and suspension components.

Remove the U-bolts.

1. Remove the four nuts.

2. Remove the two U-bolts and the front spring spacer. Discard the U-bolts.

5. Disconnect the front driveshaft. 1. Remove the four bolts and the two straps.

2. Remove the driveshaft from the pinion flange.

6. Disconnect the spring shackle. 1. Remove the nut and bolt.

2. Position the spring shackle away from the spring.

7. Detach the pushpin and remove the bolt and condenser bracket.

8. Disconnect the spring hanger. 1. Remove the nut and bolt.

2. Using a hammer, tap the spring until the spring is free from the hanger bracket.

9. Remove the spring from the vehicle.

Installation

1. Position the spring in the vehicle.

2. Install the spring into the spring hanger. 1. Position the spring into the hanger.

2. Install the bolt and nut. Do not tighten the nut and bolt at this time.

3. Install the bracket and bolt and the pushpin.

4. Install the spring into the spring shackle. 1. Position the shackle.

2. Install the bolt and nut. Do not tighten the nut and bolt at this time.

5. NOTE: The U-bolts insert through the front spring cap on the left-hand side and through the axle assembly bracket on the right-hand side.

Install the upper front spring spacer and U-bolts.

1. Position the front spring spacer and the new U-bolts.

2. Install the four nuts. Do not tighten the nuts at this time.

6. NOTE: The following step is for the left-hand shock only. The right-hand shock is similar.

Install the shock, bolt and nut onto the spring cap.

7. NOTE: The suspension must be loaded with the weight of the vehicle before the U-bolts and the leaf spring mounting bolts can be tightened. Make sure that the locating pin is correctly aligned with the axle.

Lower the vehicle onto the jack stands until the front suspension is supporting the weight of the vehicle.

8. NOTE: The U-bolts must be tightened in a criss-cross sequence. This will tighten the U-bolts evenly.

Tighten the U-bolts following the sequence.

9. Tighten the leaf spring rear retaining bolt and nut.

10. Tighten the leaf spring front retaining bolt and nut.

11. Raise the vehicle and remove the jack stands.

12. Install the front driveshaft. 1. Position the driveshaft onto the pinion flange.

2. Install the two straps and the four bolts.





Spring—Shackle


1. NOTE: Both the left side and right side spring shackles are removed and installed the same way. Only the left side is shown.

Raise and support the vehicle; refer to Section 100-02.

2. Remove the wheel and tire assembly; refer to Section 204-04.

3. Place a suitable jack under the front drive axle housing.

4. Remove the nut and bolt, and disconnect the shock absorber from the spring cap.

5. Remove the nut and bolt.

6. Remove the spring shackle from the leaf spring. 1. Lower the jack until the nut and bolt can be removed.

2. Remove the nut, bolt and the spring shackle.

7. Remove the bolts and the shackle bracket.

8. NOTE: The spring shackle retaining nuts and bolts must be tightened with the suspension supporting the weight of the vehicle.





Spring—Hanger


1. NOTE: Both the left side and the right side spring hangers are removed and installed the same way. Only the left side is shown.

Raise and support the vehicle; refer to Section 100-02.

2. Remove the wheel and tire assembly; refer to Section 204-04.

3. Place a suitable jack under the front drive axle housing.

4. Remove the nut and bolt, and disconnect the shock absorber from the spring cap.

5. Remove the nut and bolt, and lower the jack until the spring is out of the spring hanger.

6. Remove seven bolts and the spring hanger.




Manual


Vacuum Valve

Removal

1. Open the hood.

2. Disconnect the electrical connector and the vacuum harness.

3. Remove the valve. 1. Remove the bolt.

2. Loosen the bolt.

3. Remove the valve.

Installation

1. NOTE: The vacuum valve must be installed with the white cap facing upward.

Follow the removal procedure in reverse order.

SECTION 204-02: Rear Suspension

SPECIFICATIONS


Rear Suspension


Rear Suspension

GENERAL PROCEDURES

Wheel Bearing End Play


Hub

Wheel Studs

Bar and Link—Super Duty F-250, F-350, Ford Axle

Bar and Link—Super Duty F-350, Dana Axle

Bar and Link—Super Duty F-450, F-550, Dana Axle

Bar and Link—Super Duty Motorhome Chassis

Shock Absorber—Super Duty F-250, F-350, Ford Axle

Shock Absorber—Super Duty F-450, F-550, Dana Axle

Shock Absorber—Super Duty Motorhome Chassis

Spring—Super Duty F-250, F-350


SECTION 204-02: Rear Suspension 1999 F-Super Duty 250-550 Workshop Manual


Torque Specifications — Super Duty F-250, F-350 Wide Frame


Leaf Spring-to-Axle U-Bolt Nut 250 185

Leaf Spring-to-Front Spring Hanger Bracket Nut and Bolt 250 185

Leaf Spring-to-Rear Shackle Nut and Bolt 250 185

Rear Shackle-to-Frame Mounted Bracket Nut and Bolt 250 185

Shock Absorber-to-Frame Mounted Bracket Nut 62 46

Shock Absorber-to-Axle Bracket Nut and Bolt 62 46

Shock Absorber Bracket-to-Axle U-Bolt and Nut (Ford Axle) 47 35

Stabilizer Bar Retainer Bracket-to-Axle Bolt (Dana Axle) 40 30

Stabilizer Bar Retainer Bracket-to-Axle U-Bolt and Nut (Ford Axle) 47 35

Stabilizer Bar Link-to-Frame Nut 70 52

Stabilizer Bar Link-to-Stabilizer Bar Nut 70 52

Torque Specifications — Super Duty F-350 Narrow Frame








Shock Absorber Bracket-to-Axle U-Bolt and Nut (Ford Axle) 47 35

Stabilizer Bar Retainer Bracket-to-Axle Bolt (Dana Axle) 40 30

Stabilizer Bar Retainer Bracket-to-Axle U-Bolt and Nut (Ford Axle) 47 35



Torque Specifications — Super Duty F-450








Stabilizer Bar Retainer Bracket-to-Axle Bolt 80 60



Torque Specifications — Super Duty F-550








Stabilizer Bar Retainer Bracket-to-Axle Bolt 80 60



Torque Specifications — Super Duty Motorhome






Rear Spring Bracket-to-Frame Nut and Bolt 90 67

Shock Absorber-to-Frame Mounted Bracket Nut and Bolt 350 259


Stabilizer Bar Bracket Bolt-to-Axle 90 67





Rear Suspension

Super Duty F-250, F-350 Wide Frame


1 N620482-S56 Nut, M10-1.5 Hex

2 N800878-S Spacer

3 N647097-S Rivet, M10 x 25

4 4A171 Rear Axle Bumper Stop

5 4002 Rear Axle Bumper Assy

6 W704838-S428

Nut and Retainer Assy, M10 x 1.5 x 35

7 5700 Front Auxiliary Spring Bracket

8 W500593-S426

Bolt, M16-2.0 x 135 Hex

9 5776 Shackle Assy

10 N620485-S56 Nut, M16-2.0 Hex

11 N500593-S426 Bolt, M16-2.0 x 175 x 10.9

12 N605920-S2 Bolt, M10 x 1.5 x 33.5

13 N806367-S428 Nut and Retainer, M16-2.0 x 20 x 10

14 N620485-S56 Nut, M16-2.0 Hex

15 5588 Auxiliary Spring

16 5560 Rear Spring Assy

17 N811673-S428 U-Bolt, M16-2.0 x 108/225

18 5598 Rear Spring Spacer (4x4 Only)

19 5594 Auxiliary Spring Spacer

20 5798 Rear Spring Plate

21 N807044-S428 Nut and Retainer, M18-2.5 x 19 x 10

22 N806967-S426 Bolt, M18-2.5 x 139 x 10.9

23 5A636 Auxiliary Spring Bumper

24 N806085-S8 Nut and Washer Assy, M12-1.75 Hex

25 18080 Rear Shock


27 N605705-S2 Bolt, M12-1.75 Hex

28 5A771 Stabilizer Bar Assy

29 N800937-S301 Nut, M12-1.75 Hex

30 N801527-S2 Washer, M12

31 5B491 Rear Stabilizer Bar Retainer

32 5K484 Link Assy

33 N620482-S56 Nut, M10-1.5 Hex (Ford Axle Only)

34 4A047 Lower Shock Bracket ( Ford Axle Only)

35 4A047 Rear Stabilizer Bar Bracket (Ford Axle Only)

36 N811672-S428 U-Bolt, M10-1.5 x 101/152.5 (Ford Axle Only)

37 N803758-S56 U-Bolt, M10-1.5 x 137.5/161.5 (Ford Axle Only)

38 N605546-S2 Bolt, M10-1.5 x 33.5

39 N630088-S2 Washer, M10-15 x 33.5

Super Duty F-350 Narrow Frame


1 N620482-S56 Nut, M10-1.5 Hex

2 N800878-S Spacer

3 N647097-S Rivet, M10 x 25




7 5A978 Auxiliary Spring Bracket Liner — (RR)

8 W500593-S426

Bolt, M16-2.0 x 145 Hex

9 N620485-S56 Nut, M16-2.0 Hex

10 5776 Shackle Assy

11 W500593-S426

Bolt, M16-2.0 x 175 x 10.9

12 N806367-S428

Nut and Retainer, M16-2.0 x 20 x 10

13 N620485-S56 Nut, M16-2.0 Hex

14 5588 Auxiliary Spring

15 5560 Rear Spring Assy

16 N811673-S428

U-Bolt, M16-2.0 x 108/225

17 5598 Rear Spring Spacer (4x4 Only)

18 5594 Auxiliary Spring Spacer

19 5798 Rear Spring Plate

20 N804967-S426

Bolt, M18-2.5 x 139 x 10.9

21 N807044-S428

Nut and Retainer, M18-2.5 x 19 x 10

22 N811672-S428

U-Bolt, M10-1.75 x 101/152.5 (Ford Axle Only)

23 4A047 Lower Shock Bracket (Ford Axle Only)

24 N605705-S2 Bolt, M12-1.75 x 70 Hex


26 N806496-S301

Nut and Washer Assy, M12-1.75 Hex


28 N803758-S56 U-Bolt, M10-1.75 x 137.5/161.5 (Ford Axle Only)

29 4A047 Rear Stabilizer Bar Bracket (Ford Axle Only)

30 N800937- Nut, M12-1.75 Hex

S301

31 N801527-S2 Washer, M12




35 5K484 Link Assy

36 N801527-S2 Washer, M12

37 N800937-S301

Nut, M12-1.75 Hex

38 N605546-S2 Bolt, M10-1.5 x 33.5 Hex

39 N630088-S2 Washer, M10-1.5 x 33.5

Super Duty F-450 and F-550


1 N605920-S2 Bolt, M10-1.5 x 20 Hex

2 N620482-S56 Nut, M10-1.5 Hex

3 N647098-S Rivet, M10 x 35



6 N805007-S100 Nut and Retainer Assy, M12-1.75 Hex

7 N805136-S56 Nut and Retainer Assy, M12-1.75 x 80

8 W500593-S426 Bolt, M16-2.0 x 145 Hex

9 N620485-S56 Nut, M16-2.0 Hex


11 N805041-S2 Bolt, M16-2.0 x 145 Hex

12 5775 Rear Shackle Bracket

13 N808591-S2 Bolt, M12-1.75 x 49.5 Hex

14 N806367-S428 Nut, M16-2.0 Hex

15 5A978 Auxiliary Spring Bracket Liner

16 5700 Rear Auxiliary Spring Bracket

17 N811826-S428 U-Bolt, M20-2.5 x 98.3 x 400

18 5A975 Rear Spring Assy

19 — Rear Axle Assy (Dana S135)

20 N805028-S56 Nut, M20-2.5 Hex

21 5796 Rear Spring Seat Cap

22 N805444-S100 Bolt, M20-2.5 x 145 Hex


24 5785 Front Hanger Bracket


26 W500760-S428 Bolt, M14-2.0 x 50 Hex


28 5K484 Stabilizer Bar Link Assy

29 N605814-S426 Bolt, M12-1.75 x 30 Hex


31 N800937-S301 Nut, M12-1.75 Hex

32 N801527 Washer, M12


34 N605705-S2 Bolt, M12-1.75 x 70 Hex


36 N806085-S8 Nut and Washer Assy, M12 Hex

Super Duty F-450


1 N605920-S2 Bolt, M10-1.5 x 20 Hex

2 N647098-S Rivet, M10 x 35



5 N620482-S56 Nut, M10-1.5 Hex



8 N605705-S2 Bolt, M12-1.75 x 70 Hex

9 W500593-S426 Bolt, M16-2.0 x 145 Hex

10 N620485-S56 Nut, M16-2.0 Hex




14 N647100-S Rivet 10 x 35

15 5A978 Auxiliary Spring Bracket Liner

16 N806367-S428 Nut, M16-2.0 Hex

17 N808591-S2 Bolt, M12-1.75 x 49.5 Hex

18 5775 Rear Shackle Bracket


20 N805041-S2 Bolt, M16-2.0 x 145 Hex

21 5A975 Rear Spring Assy

22 5796 Rear Spring Seat Cap

23 N805028-S56 Nut, M20-2.5

24 N811362-S56 U-Bolt, M20-2.5 x 100 x 364

25 N805444-S100 Bolt, M20-2.5 x 145 Hex

26 5785 Front Hanger Bracket

27 N805161-S56 Nut and Retainer, M20-2.5 Hex

28 W500760-S428 Bolt, M14-20 x 50 Hex



31 N800937-S301 Nut, M12-1.75 Hex

32 N801527-S2 Washer, M12



35 N605920-S2 Bolt, M10-1.5 x 33.5 Hex


Super Duty Motorhome



2 5A771 Rear Stabilizer Bar Assy

3 N601423-S2 Bolt, M12-1.5 x 100

4 N800937-S427 Nut, M12-1.75

5 5L496 Rear Stabilizer Bar Link Mounting Bracket

6 W500443-S426 Bolt, M12-1.75 x 35

7 N803447-S36MC

Washer, M12

8 5K484 Rear Stabilizer Bar Link Assy

9 W500541-S426 Bolt, M12-1.75 x 50



Rear Suspension




Wheel Bearing End Play




Hub

For additional information, refer to Section 205-02C.



Wheel Studs

Special Tool(s)

C-Frame and Screw 211-023 (T74P-3044-A1)

Removal



3. On vehicles equipped with dual rear wheels, go to Step 7.

4. Remove the disc brake caliper and rotor. For additional information, refer to Section 206-04.

5. Remove the rear wheel hub assembly. For additional information, refer to Section 205-02C.

6. Using a suitable press, remove the wheel bolt from the wheel hub and discard.

7. NOTE: For vehicles equipped with dual rear wheels, use the C-Frame and Clamp Assembly Tool to remove the wheel bolt on the vehicle.

Remove the wheel bolt from the wheel hub and discard.

Installation

1. Using a suitable press, install the new wheel bolt aligning the serrations in the wheel hub flange made by the original wheel bolt.

2. On vehicles with dual rear wheels, install the new wheel bolt aligning the serrations in the wheel hub flange made by the original wheel bolt.

• Place four flatwashers over the outside end of the wheel bolt and thread a standard wheel nut with the flat side against the washers.

• Tighten the wheel nut until the wheel bolt head seats against the back side of the hub flange.

3. Remove the wheel nut and flatwashers.

4. On vehicles with dual rear wheels, go to Step 7.

5. Install the rear wheel hub assembly. For additional information, refer to Section 205-02A.

6. Install the disc brake caliper and rotor. For additional information, refer to Section 206-04.





Bar and Link—Super Duty F-250, F-350, Ford Axle

Removal

CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. Install new parts with the same part number or an equivalent part if installation is necessary. Do not use an installation part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts.

NOTE: Super Duty F-250, F-350 Wide Frame shown, Super Duty F-350 Narrow Frame similar.


2. Remove the nuts from both lower ends of the stabilizer bar links and remove the washers.

3. Remove the nuts and washers from both upper ends of the stabilizer bar links-to-frame and remove the links.

4. Remove the nuts from both stabilizer bar retainer-to-axle brackets and remove the stabilizer bar retainers, stabilizer bar mounting brackets, U-bolts and the stabilizer bar.

Installation




Bar and Link—Super Duty F-350, Dana Axle

Removal


NOTE: Super Duty F-350 Wide Frame shown, Super Duty F-350 Narrow Frame similar.




4. Remove the bolts from both stabilizer bar retainer-to-axle brackets and remove the stabilizer bar.

Installation




Bar and Link—Super Duty F-450, F-550, Dana Axle





3. Remove the nuts and washers from both upper ends of the stabilizer bar links and remove the links.


• Remove the stabilizer bar bushings if necessary.

5. To install, reverse the removal procedure. • Install all new fasteners.



Bar and Link—Super Duty Motorhome Chassis

Removal



2. Remove the nuts and bolt from both lower ends of the stabilizer bar links.



Installation




Shock Absorber—Super Duty F-250, F-350, Ford Axle

Removal


CAUTION: The low pressure gas shock absorbers are charged with nitrogen gas. Do not attempt to open, puncture or apply heat to shock absorbers.

NOTE: Super Duty F-250, F-350 Ford axle shown, Super Duty F-350 Dana axle similar.


2. Using a suitable jack, support the rear axle.

3. Remove the shock absorber lower retaining nut and bolt.

4. Remove the nut from the upper shock absorber mounting bracket and remove the shock.

Installation




Shock Absorber—Super Duty F-450, F-550, Dana Axle

Removal







Installation




Shock Absorber—Super Duty Motorhome Chassis

Removal



NOTE: Super Duty Motorhome Chassis Dana axle shown, Super Duty Motorhome Chassis Ford axle similar.





Installation





Removal




3. Support the rear axle with a suitable jack.

4. Remove the U-bolt retaining nuts and remove the U-bolts.

5. Remove the rear spring upper plate.

6. Remove the nut and bolt from the rear spring front hanger bracket.

7. Remove the lower nut and bolt from the rear spring shackle bracket. Remove the rear spring assembly.

8. If equipped, remove the auxiliary spring and auxiliary spring spacer.

9. Remove the nut and bolt from the rear spring shackle assembly and remove the rear spring shackle.

Installation





Removal




3. Support the rear axle with a suitable jack.

4. Remove the U-bolt retaining nuts and remove the spring plate.

5. Remove the U-bolts.

6. Remove the nut and bolt from the front spring hanger bracket.

7. Remove the lower nut and bolt from the rear spring shackle bracket. Remove the rear spring assembly.

8. On 4x4 vehicles, remove the spacer plate.

9. Remove the nut and bolt from the rear spring shackle assembly and remove the rear spring shackle.

10. Remove the auxiliary spring. 1. Remove the auxiliary spring retaining nut.

2. Remove the upper spring plate.

3. Remove the auxiliary spring.

4. Remove the auxiliary spring spacer.

Installation


SECTION 204-04: Wheels and Tires

SPECIFICATIONS


Safety Precautions

Wheels And Tires


Wheels And Tires


Road Test

Symptom Chart

Component Tests

Tire and Wheel Runout

Tire Runout

Wheel Runout

GENERAL PROCEDURES

Wheel Leaks


Wheel and Tire — Single

Wheel and Tire — Dual Wheel and Tire

SECTION 204-04: Wheels and Tires 1999 F-Super Duty 250-550 Workshop Manual



Item Specification

Tires See Safety Certification Sticker Located on Driver Door Jamb.

Cleaners — Wheel

Custom Bright Metal Cleaner 8A-19522-A

ESR-M5B194-B

Wheel Rim Runout

Type Wheel Max. Radial Runout Max. Lateral Runout

Aluminum 1.21 mm (0.04 in) 1.52 mm (0.06 in)

Steel 1.21 mm (0.04 in) 1.52 mm (0.06 in)

Tire Runout Specifications

Type Wheel Max. Radial Runout Max. Lateral Runout

Aluminum 1.27 mm (0.05 in) 1.27 mm (0.05 in)

Steel 1.27 mm (0.05 in) 1.27 mm (0.05 in)


Description Nm lb-ft

8-Lug M14 wheel bolts 224 165

Spare tire carrier bolts 20 15



Safety Precautions

WARNING: Never run the engine with one wheel off the ground, for example, when changing a tire. The wheel(s) resting on the ground could cause the vehicle to move.

WARNING: The tire and wheel must always be properly matched. It is very important to determine the size of each component before any assembly operations commence. Failure to adhere to these instructions can result in an explosive separation and cause serious bodily injury or death.

WARNING: Aftermarket aerosol tire sealants are extremely flammable. Always question the customer to make sure these products have not been used.

WARNING: Aftermarket wheel assemblies may not be compatible with the vehicle. Use of incompatible wheel assemblies can result in equipment failure and possible injury. Use only approved wheel assemblies.

WARNING: Use only wheels and lug nuts that have been designed for current model year Ford trucks. Aftermarket wheels or lug nuts may not fit or function properly, and can cause personal injury or damage the vehicle.

WARNING: Always wear safety goggles or a face shield when performing any work with tire and wheel assemblies.

CAUTION: Do not clean aluminum wheels with steel wool, abrasive-type cleaners or strong detergents. Use Custom Bright Metal Cleaner 8A-19522-A or equivalent meeting Ford specifications ESR-M5B194-B.

CAUTION: Reduce the air pressure as much as possible by pushing the valve core plunger in prior to removing the valve core. Avoid working in a position in which the face or body is directly over a tire in which there is pressure.

When performing any inspection or repair procedures on wheels (1007) and tires, follow the preceding safety precautions.



Wheels And Tires

WARNING: Do not mix different types of tires, such as radial, bias, or bias-belted, on the same vehicle except in emergencies. Vehicle handling can be seriously affected and can result in loss of control.

Factory-installed tires and wheels are designed to operate satisfactorily with loads up to and including full-rated load capacity when inflated to recommended inflation pressures.



Wheels And Tires

Special Tool(s)

Radial Runout Gauge 418-F123 (007-0056A) or Equivalent


WARNING: A vehicle equipped with a Traction-Lok® differential will always have both wheels driving. If, while the vehicle is being serviced, only one wheel is raised off the floor and the rear axle is driven by the engine, the wheel on the floor could drive the vehicle off the stand or jack. Be sure both rear wheels are off the floor.

WARNING: Never run the engine with one wheel off the ground, for example, when changing a tire. The wheel(s) resting on the ground could cause the vehicle to move.

WARNING: Do not balance the wheels and tires while they are mounted on the vehicle. Possible tire disintegration or differential failure could result, causing personal injury and extensive component damage. Use off-vehicle wheel and tire balancer only.

Be sure to follow the warnings when performing inspection and verification.

Road Test

Verify the customer concern by performing a road test on a smooth road. If any vibrations are apparent, go to Section 100-04.

To maximize tire performance, inspect for signs of improper inflation and uneven wear, which may indicate a need for balancing, rotation, or front suspension alignment.

Correct tire pressure and driving techniques have an important influence on tire life. Heavy cornering, excessively rapid acceleration and unnecessary sharp braking increases tire wear.

Replacement tires must follow the recommended:

• tire sizes. • speed rating. • load range. • radial construction type.

Use of any other tire size or type can seriously affect:

• ride. • handling. • speedometer/odometer calibration. • vehicle ground clearance. • tire clearance between the body and chassis. • wheel bearing life. • brake cooling.

Wheels need to be replaced when:

• bent. • cracked. • dented. • heavily rusted. • leaking. • they have elongated wheel hub bolt holes. • they have excessive lateral or radial runout.

Wheel and tire assemblies are attached by eight integral two-piece swiveling lug nuts.

It is mandatory to use only the tire sizes recommended on the tire chart attached to the vehicle. Larger or smaller tires can damage the vehicle, affect durability, and require changing the speedometer calibration. Make sure wheel size and offsets match those recommended for the tire in use.

1. Inspect for signs of uneven wear that may indicate a need for balancing, rotation, front suspension alignment, damaged tie rod, or steering components.

2. Check tires for: • cuts. • stone bruises. • abrasions. • blisters. • embedded objects.

3. Tread wear indicators are molded into the bottom of the tread grooves. Replace the tire when the indicator bands become visible.

Symptom Chart

SYMPTOM CHART


• Tires Show Excess Wear on Edge of Tread

• Underinflated tires. • ADJUST air pressure in tires.

• Vehicle overloaded. • RETURN vehicle — NOTIFY customer of overload condition.

• High-speed cornering. • RETURN vehicle — NOTIFY customer of cause of condition.

• Incorrect wheel alignment.

• SET toe to specification; for additional information REFER to Section 204-00.

• Tires Show Excess Wear in Center of Tread

• Tires overinflated. • ADJUST air pressure.

• Other Excessive Tire Wear Problems

• Improper tire pressure. • ADJUST pressure.

• Loose or leaking shock absorbers.

• TIGHTEN or REPLACE as necessary.

• Front end out of alignment.

• ALIGN front end; for additional information REFER to Section 204-00.

• Front wheel bearings out • REFER to Section 204-00 for inspection

of adjustment. procedure.

• Loose, worn or damaged suspension components.

• For additional information REFER to Section 204-00.

• Wheel and tire assembly out of balance.

• BALANCE wheel and tire assembly.

• Excessive lateral or radial runout of wheel or tire.

• REFER to Component Tests in this section.

• Improper tire rotation intervals.

• ADVISE customer of condition.

• Wobble or Shimmy

• Damaged wheel bearings.


• Loose or damaged suspension components.


• Bent wheel. • REPLACE as necessary.

• Damaged tire. • REPLACE as necessary.

• Loose lug nuts. • TIGHTEN to specification.

• High-Speed Shake

• Wheel hub face/pilot/bolt circle runout.

• Tires/wheels. • Wheel bearings. • Suspension/steering

linkage. • Engine. • Transmission. • Brake rotor.


• Vehicle Vibration

• Driveline — engine. • Tires.


Component Tests

Tire and Wheel Runout

Excessive radial and lateral runout of a wheel and tire assembly can cause roughness, vibration, wheel tramp, tire wear, and steering wheel tremor.

Before checking runout, and to avoid false readings caused by temporary flat spots in the tires, check runout only after the vehicle has been driven far enough to warm the tires.

The extent of the runout is measured with the radial runout gauge. All measurements are made on the vehicle with the tires inflated to recommended inflation pressures and with the front wheel bearings adjusted to specifications.

Tire Runout

Measure radial and lateral tire runout at the positions shown in the illustration. Runout should not exceed specifications.

Wheel Runout

Measure radial and lateral wheel runout at the positions shown in the illustration. Runout should not exceed specifications.



Wheel Leaks

1. There is no approved repair method for forged aluminum or steel wheels. If the wheel is damaged or has an air leak, a new wheel must be installed.



Wheel and Tire — Single

Removal

WARNING: Use only the integral two-piece swiveling wheel nuts. Do not attempt to use cone-shaped one-piece wheel nuts on these vehicles. If used, cone-shaped one-piece wheel nuts can come loose in vehicle operation. Do not attempt to use past model wheels, which have cone-shaped wheel hub bolt nut seats, on this vehicle. Do not attempt to use present design wheels and wheel nuts on past model wheel hubs. Attempted use of intermixed wheels can lead to damage to the wheel mounting system and could result in wheels coming loose.

1. Remove the wheel cover, if equipped.

2. CAUTION: Do not use heat to loosen a seized wheel nut. Heat can damage the wheel and wheel bearings.

NOTE: Do not remove the wheel nuts at this time.

With the weight of the vehicle still on the tires, loosen the wheel nuts.

3. Raise the vehicle until the wheel and tire assembly clears the floor. For additional information, refer to Section 100-02.

4. Remove the wheel nuts.

5. Remove the wheel and tire assembly.

Installation

1. WARNING: When a wheel is installed, always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the front disc brake hub and rotor that contacts the wheel. Installing wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the wheel nuts to loosen and the wheel to come off while the vehicle is in motion, resulting in loss of control.

Position the wheel and tire assembly on the vehicle.

2. CAUTION: Do not apply motor oil to the wheel nut threads or the wheel stud threads.

On all two-piece flat wheel nuts, apply one drop of motor oil between the flat washer and the nut. If corrosion exists, or the integral two-piece swiveling wheel nut does not rotate freely, install new swiveling wheel nuts as necessary.

• Install the wheel nuts loosely.

3. Turn the wheel until one wheel nut is at the top of the wheel hub bolt circle. Tighten the wheel nut until snug. In a crisscross-type pattern, tighten the remaining wheel nuts until snug to minimize runout.


5. CAUTION: Failure to tighten the wheel nuts in the sequence shown can result in high wheel and tire runout, which will speed up the development of brake roughness, shudder and vibration.

CAUTION: Torque specifications are for nut and bolt threads that are free of dirt and rust. Use only Ford-recommended replacement fasteners.

With the weight of the vehicle on the tires, tighten the wheel nuts to specification in the sequence shown.

6. Install the wheel cover, if equipped.

7. Advise the customer that the wheel nuts need to be retightened at 800 km (500 miles) after wheel change or any other time the wheel nuts have been loosened. This is required to permit the wheel clamping system to seat correctly so that the wheel nuts will hold a uniform clamp load and remain fully tightened.



Wheel and Tire — Dual Wheel and Tire

Removal

1. WARNING: Use only the integral two-piece swiveling wheel nuts. Do not attempt to use cone-shaped one-piece wheel nuts on these vehicles. If used, cone shaped one-piece wheel nuts can come loose in vehicle operation. Do not attempt to use past model wheels, which have cone-shaped wheel hub bolt nut seats, on this vehicle. Do not attempt to use present design wheels and wheel nuts on past model wheel hubs. Attempted use of intermixed wheels can lead to damage to the wheel mounting system and could result in wheels coming loose.

Remove the wheel cover, if equipped.

2. CAUTION: Do not use heat to loosen a seized wheel nut. Heat can damage the wheel and wheel bearings.

NOTE: Do not remove the wheel nuts at this time.

With the weight of the vehicle still on the tires, loosen the wheel nuts.


4. Remove the wheel nuts.

5. Remove the outer wheel and tire assembly.

6. Remove the inner wheel and tire assembly.

Installation

1. CAUTION: It is imperative that the stamped indents located on the tire bead portion of the wheels are placed as close to 180 degrees from each other while still allowing access to the valve stem on the inside wheel. Failure to correctly install the wheel and tire assemblies can result in a vibration condition.

CAUTION: Do not apply motor oil to the wheel nut threads or the wheel stud threads.

Install the inner and outer wheel and tire assemblies.

1. Position the inner wheel and tire assembly onto the axle.

2. Note the location of the alignment mark.

3. Position the outer wheel and tire assembly.

4. Position the alignment mark on the outer wheel and tire assembly as close to 180 degrees away from the alignment mark on the inner wheel and tire assembly.

5. The valve stem on the inner wheel and tire assembly must be aligned with one of the hand holes in the outer wheel and tire assembly.

6. Install the wheel nuts loosely. � On all two-piece flat wheel nuts, apply one drop of motor oil between the

flat washer and the nut.


3. CAUTION: Failure to tighten the wheel nuts in the sequence shown can result in high wheel and tire runout, which will speed up the development of brake roughness, shudder and vibration.

CAUTION: Torque specifications are for nut and bolt threads that are free of dirt and rust. Use only Ford recommended replacement fasteners.

With the weight of the vehicle on the tires, tighten the wheel nuts to specification in the sequence shown.

4. Install the wheel cover, if equipped.

5. Advise the customer that the wheel nuts need to be retightened at 160 km (100 miles) and then again at 800 km (500 miles) after wheel change or any other time the wheel nuts

have been loosened. This is required to permit the wheel clamping system to seat correctly so that the wheel nuts will hold a uniform clamp load and remain fully tightened.

GROUP 05: Driveline

SECTION 205-00: Driveline System — General Information

SECTION 205-01: Driveshaft

SECTION 205-02A: Rear Drive Axle/Differential — Dana 80

SECTION 205-02B: Rear Drive Axle/Differential — Dana S135

SECTION 205-02C: Wheel Hubs and Bearings — Full Floating Axle — Dana

SECTION 205-02D: Rear Drive Axle/Differential — Ford 10.50-Inch Ring Gear

SECTION 205-02E: Wheel Hubs and Bearings — Full Floating Axle — Ford

SECTION 205-03: Front Drive Axle/Differential

SECTION 205-00:

Driveline System — General Information

SPECIFICATIONS


Driveline System


Driveline System


Universal Joint (U-Joint) Inspection

Inspection For Bent Rear Axle Housing

Noise Acceptability

Preliminary Diagnosis

Road Test

Analysis of Leakage

Analysis of Vibration

Non-Axle Noise

Axle Noise

Total Backlash Check

Symptom Chart

Component Tests

Driveline Vibration

Runout Check — Circular Pinion Flange

Runout Check — Half-Round Companion Flange

Differential Check — Ford Traction-Lok® Road Test (Ford)

Differential Check — Tractech® Truetrac®

Differential Check — Powr-Lok® Road Test (Dana)

Tooth Contact Pattern Check — Gearset, Dana S135

Tooth Contact Pattern Check — Gearset, Except Dana S135

GENERAL PROCEDURES

Axle Housing Casting Porosity (Holes in Casting) Repair





Item Specification

Lubricants

Front Axle

Premium Rear Axle Lubricant XY-80W90-QL

WSP-M2C197-A

Rear Axle

Ford Rear Axle: SAE 75W-140 Synthetic Rear Axle Lubricant F1TZ-19580-B

WSL-M2C192-A

Dana 80 Rear Axle: SAE 75W-90 Synthetic Rear Axle Lubricant XY-75W90-GLS

—

Dana S135 Rear Axle: SAE 75W-90 Synthetic Rear Axle Lubricant F1TZ-19580-B

WSL-M2C192-A

Additive Friction Modifier C8AZ-19B546-A

EST-M2C118-A

Driveshaft Slip-Yoke

Premium Long-Life Grease XG-1-C ESA-M1C75-B

Capacities

Front Axle Liters (Pints) 2.8 (5.9)

Ford Rear Axle Liters (Pints) 3.26 (7.0)a

Dana 80 Rear Axle (Conventional Differential) Liters (Pints) 4.0 (8.5)

Dana 80 Rear Axle (Trac-Lok®) Liters (Pints) 3.8 (8)

Dana S135 Rear Axle Liters (Pints) 11.6 (24.5)

Friction Modifier ML (Ounces)

236.56 (8)

Sealants

Pipe Sealant with Teflon® D8AZ-19554-A WSK-M2G350-A2

Devcon Aluminum Liquid F2 M-3D35A(E)

Stud and Bearing Mount EOAZ-19554-BA WSK-M2G349-A1

a Service refill capacities are determined by filling the axle to the bottom of the filler hole. On Traction-Loc® axles, always add friction modifier first.

Rear Driveline Angle Specifications — Excursion

Wheel Base (inch)

Engine (L) Trans.

Axle Ratio

Angles at Maximum

GVWR (Deg) Trans.

Angles at Maximum

GVWR (Deg) Pinion

Angles at Curb (Deg) Trans.

Angles at Curb (Deg) Pinion

4 x 2

137 5.4 4R100 3.73 1.43 2.00 0.19 2.00

137 5.4 4R100 4.10 1.43 2.00 0.19 2.00

137 6.8 4R100 3.73 1.44 1.99 0.19 2.00

137 6.8 4R100 4.30 1.44 1.99 0.19 2.00

137 7.3 4R100 3.73 1.50 1.93 0.20 2.01

4 x 4

137 5.4 4R100 3.73/4.10 0.17 0.94 2.21 0.52

137 6.8 4R100 3.73/4.30 0.17 0.94 2.21 0.52

137 7.3 4R100 3.73 0.17 0.94 2.32 0.41




Driveline System

Driveline Component Locations


1 3001 Front Axle Assy

2 4001 Rear Axle Assy

3 4602 Driveshaft

4 4635 Universal Joints

The driveline transfers engine torque to the drive wheels. On 2-wheel drive vehicles, power is transmitted through the transmission to the driveshaft (4602) and then to the rear axle assembly (4006).

On 4-wheel drive vehicles, power is transmitted through the transmission and the transfer case (7A195). The transfer case directs the power through the rear driveshaft and then to the rear axle (4001). When engaged, it also transmits power through the front driveshaft to the front axle assembly (3001).

A two-piece driveshaft is used in some longer wheelbase light truck models. As compared with a one-piece installation, the two-piece design includes a front or "coupling" shaft, a rubber-insulated frame-mounted driveshaft center bearing bracket, a splined slip joint and an intermediate universal joint at the front of the rear driveshaft.

For additional information on the front axle assembly, refer to Section 205-03.

For additional information on the driveshaft, refer to Section 205-01.

For additional information on the rear axle, refer to Section 205-02A, Section 205-02B or Section 205-02D.

The engine angle is built into the engine mounts. If the engine angle is out of specification, the engine mounts must be inspected for damage.

Vehicle Certification (VC) Label Example

The vehicle certification (VC) label is located in the driver door jamb. The first two digits of the axle code indicate the rear axle and the third digit refers to the front axle, if so equipped. For additional information on the VC label, refer to Section 100-01.

Dana S135 Rear Axle Identification Tag

Item Description

1 Carrier Identification Tag

2 Dana Part Number

3 Customer Part Number (Optional)

4 Julian Date Code

5 Line Set Number (Optional)

6 Axle Ratio

7 Last Six Digits of the Vehicle Serial Number (Optional)

8 Axle Assembly Identification Tag

9 Model

Dana 80 Rear Axle Identification Tag

Item Description

1 Axle Ratio (Part of 4001)

2 Axle Assy Number (Prefix Letters) (Part of 4001)

3 Axle Assy Number (Suffix Letters) (Part of 4001)

4 Dana Part Number (Part of 4001)

5 Included on Limited Slip Only (Part of 4001)

Ford Rear Axle Identification Tag

Item Description

1 Plant Code

2 Axle Ratio

3 Denotes Traction-Lok®

4 Ring Gear Diameter

5 Build Year

6 Build Month

7 Build Day

Axle Identification Tag Denoting Interchangeability Affected Internally

Item Description

1 Plant Code

2 Denotes Interchangeability Affected Internally

3 Axle Ratio

4 Denotes Traction-Lok®

5 Ring Gear Diameter (Inch)

6 Build Year

7 Build Month

8 Build Day

CAUTION: The axle identification tag is the official identifier. Do not damage the tag. Always reinstall the tag after removing it for axle inspection/repair.

The axle identification tag identifies a particular axle design, a specific ratio, and if it is a conventional or limited slip (Traction-Lok®) type. In addition, the plant code will not change as long as that particular axle assembly never undergoes an external design change. If, however, an internal design change takes place during the production life of the axle and that internal change affects parts interchangeability, a dash and numerical suffix is added to the plant code. This means that as an assembly both axles are interchangeable; however, internally they are different. Therefore, each requires different internal parts at the time of repair.

SECTION 205-00: Driveline System — General

Information 1999 F-Super Duty 250-550

Workshop Manual


Driveline System

Special Tool(s)

Anglemaster II Driveline Inclinometer 164-R2402 or Equivalent

Clamp Plate 205-320 (T92L-4851-C)

Companion Flange Holding Tool 205-126 (T78P-4851-A)

Companion Flange Runout Gauge 205-319 (T92L-4851-B)

Companion Flange Runout Gauge 205–323 (T92T-4851-D)

Dial Indicator with Magnetic Base 100-D002 (D78P-4201-B) or Equivalent

Electronic Vibration Analyzer 014-00344

Flange Holder 205-012 (T57T-4851-B)

Gauge Pin 205–325 (T92T-4851-F)

Gauge Pin 205–326 (T92T-4851-G)


Certain axle and driveline trouble symptoms are also common to the engine, transmission, wheel bearings, tires, and other parts of the vehicle. For this reason, verify that the cause of the trouble is in the axle before adjusting, repairing, or installing new parts. For additional information, refer to Section 100-04.

Certain symptoms may be caused by Ford Traction-Lok® differentials. Check the vehicle certification label and the axle identification tag to determine the type of differential. For additional information, refer to Section 100-01.

Universal Joint (U-Joint) Inspection

Place the vehicle on a frame hoist and rotate the driveshaft by hand. Check for rough operation or seized U-joints. Install a new U-joint if it shows signs of seizure, excessive wear, or incorrect seating. For additional information, refer to Section 205-01.

Inspection For Bent Rear Axle Housing

1. Raise and support the vehicle. For additional information, refer to Section 100-02. Allow the rear axle to be freely suspended.

2. Use white chalk or paint to mark a vertical line on the center of each rear tire.

3. Adjust both wheels so that the markings face the front of the vehicle. With a tape measure, measure the distance between the marks and record this reading (front reading).

4. Rotate the rear wheels so the markings are directly underneath the vehicle. Measure the distance between the marks and record this reading (bottom reading).

5. Rotate the rear wheels so the markings face the rear of the vehicle. Measure and record the distance between the marks (rear reading).

6. Compare the front and the rear readings (Steps 3 and 5) to find the toe-in or toe-out condition.

• Toe-in occurs when the front measurement is less than the rear measurement. • Toe-out occurs when the rear measurement is less than the front measurement.

7. To determine camber, find the average of the front and the rear measurements (Steps 3 and 5). Subtract the bottom reading (Step 4) from this number.

8. Positive (+) camber is when the bottom reading is less than the average of the front and rear readings. Negative (-) camber is when the bottom reading is greater than the average of the front and rear readings.

9. The results of the calculations in Steps 6 and 7 must conform to the following specifications: Toe-in: 0 — 1/16 inch. Toe-out: 0 — 3/16 inch. Camber: 0 ± 5/32 inch. If the differential housing does not meet these specifications, install a new differential housing. For additional information, refer to Section 205-02A, Section 205-02B or Section 205-02D.

10. After installing a new differential housing, repeat Steps 2 through 7.

Noise Acceptability

NOTE: A gear-driven unit will produce a certain amount of noise. Some noise is acceptable and audible at certain speeds or under various driving conditions such as a newly paved blacktop road. Slight noise is not detrimental to the operation of the axle and is considered normal.

With the Ford Traction-Lok® differential, slight chatter noise on slow turns after extended highway driving is considered acceptable and has no detrimental effect on the locking differential function.

Preliminary Diagnosis

Question the Customer

The preliminary diagnosis starts with the customer interview. The history of the concern must be investigated: When was it first noticed? Did it appear suddenly or gradually? Did any abnormal occurrence coincide with or precede its appearance such as pothole or curb impacts, minor collisions, etc.)? Were there any repair procedures carried out or new parts installed previously? It is also necessary to know any special conditions affecting the appearance and degree of the concern, such as road speed, type of road, drive mode, engine temperature, ambient temperature, etc.

A gradual appearance of the concern indicates a deterioration of a component, such as tires or front wheel bearings.

A sudden appearance of the concern could indicate a lost wheel balance weight.

Road Test

A road test is mandatory for any customer concern of noise/vibration that is not verified by the on-hoist check of chassis components. The Vehicle Road Test Evaluation form is arranged to record the conditions heard or felt during this test.

The road test form lists four operating conditions or modes in which some axle noises come and go: DRIVE, CRUISE, COAST, and FLOAT.

Mode Conditions

DRIVE Accelerating the vehicle; a definite throttle depression applying engine torque.

CRUISE Maintaining a constant speed with the throttle applied.

COAST Decelerating with the throttle closed.

FLOAT Controlled deceleration; backing the throttle continually to prevent either braking or accelerating torque from the engine.

Operate the vehicle in all four modes and record those in which the noise occurs. Write down the kilometers-per-hour (miles-per-hour) range at which both noise and vibration occur. Evaluate rear axle noise with the transmission in DIRECT DRIVE and not in OVERDRIVE. Transmission noise can be mistaken for rear axle noise when in OVERDRIVE.

Vehicle Road Test Evaluation Form

Analysis of Leakage

Clean up the leaking area enough to identify the exact source.

A plugged differential housing vent can cause excessive pinion seal lip wear due to internal pressure buildup.

Verify the axle lubricant level is correct; refer to Specifications in this section.

Axle Vent

NOTE: If the vent cannot be cleared, install a new vent.

A plugged vent will cause excessive seal lip wear due to internal pressure buildup. If a leak occurs, check the vent. Verify the vent hose is not kinked. Remove the hose from the vent nipple and clear the hose of any foreign material. While the hose is removed, pass a length of mechanics wire or a small diameter Allen wrench in and out of the vent to clean it. Connect the hose when done.

Flange Yoke Seal

Leaks at the axle drive pinion seal originate for the following reasons:

• Seal was installed incorrectly. • Poor quality seal journal surface.

Any damage to the seal bore (dings, dents, gouges, or other imperfections) will distort the seal casing and allow leakage past the outer edge of the axle drive pinion seal.

The axle drive pinion seal can be torn, cut, or gouged if it is not installed carefully. The spring that holds the axle drive pinion seal against the pinion flange may be knocked out and allow leakage past the lip.

The rubber lips can occasionally become hard (like plastic) with cracks at the oil lip contact point. The contact point on the pinion flange may blacken, indicating excessive heat. Marks, nicks, gouges, or rough surface texture on the seal journal of the pinion flange will also cause leaks.

Axle drive pinion seal wear 1.27 mm (0.050 inch) or greater is considered excessive.

Install a new pinion flange if any of these conditions exist.

Metal chips or sand trapped at the sealing lip may also cause oil leaks. This can cause a wear groove on the pinion flange and heavy pinion seal wear.

When a seal leak occurs, install a new seal and check the vent and the vent hose to verify that they are clean and free of foreign material.

Drive Pinion Nut

CAUTION: Follow the correct procedure for setting the bearing preload when the nut is installed. For additional information, refer to Section 205-02A, Section 205-02B or Section 205-02D for the rear axle or Section 205-03 for the front axle.

On some high-mileage units, oil may leak past the threads of the pinion nut. This condition can be corrected by removing the nut and applying Pipe Sealant with Teflon® D8AZ-19554-A or equivalent meeting Ford specification WSK-M2G350-A2 on the threads and nut face.

Wheel Hub Oil Seals

Wheel hub oil seals are susceptible to the same kinds of damage as axle drive pinion seals if installed incorrectly. The seal bore must be clean and the lip handled carefully to avoid cutting or tearing it. Spindle journal surface must be free of nicks, gouges, and rough surface texture. For additional information on wheel hub oil seals, refer to Section 205-02C or Section 205-02E.

Analysis of Vibration

WARNING: A vehicle equipped with a Ford Traction-Lok® differential or a Tractech® Truetrac® differential will always have both wheels driving. If only one wheel is raised off the floor and the rear axle is driven by the engine, the wheel on the floor could drive the vehicle off the stand or jack. Verify that both rear wheels are off the floor.

Few vibration conditions are caused by the front or rear axle. On a vibration concern, follow the diagnosis procedure in Section 100-04 unless there is a good reason to suspect the axle.

Tires

WARNING: Do not balance the wheels and tires while they are mounted on the vehicle. Possible tire disintegration/differential failure could result, causing personal injury/extensive component damage. Use an off-vehicle wheel and tire balancer only.

Most vibration in the rear end is caused by tires or driveline angle.

Vibration is a concern with modern, high-mileage tires if they are not "true" both radially and laterally. They are more susceptible to vibration around the limits of radial and lateral runout of the tire and wheel assembly. They also require more accurate balancing. Wheel and tire runout checks, truing and balancing are normally done before an axle inspection. For additional information, refer to Section 204-04.

Driveshaft

1. Road test the vehicle to determine the critical vibration points. Note the road speed, the engine RPM, and the shift lever positions at which the vibration occurs.

2. Stop the vehicle, place the transmission lever in neutral and run the engine through the critical speed ranges determined in Step 1.

3. If no vibration is felt, balance the driveshaft. For additional information, refer to Driveline Vibration in this section.

Driveline Angle

Driveline angularity is the angular relationship between the engine crankshaft (6303), the driveshaft, and the rear axle pinion. Factors determining driveline angularity include ride height, rear spring, and engine mounts.

Driveline Angle

Item Description

1 Bottom of the frame

2 Engine crankshaft centerline

3 Engine angle

4 Driveshaft and coupling shaft centerline

5 Driveshaft and coupling shaft angle

6 Rear axle pinion centerline

7 Axle pinion angle

Calculate the driveline operating angles as follows.

1. Preliminary setup procedures. 1. Inspect the U-joints for correct operation.

2. Park the vehicle on a level surface such as a drive-on hoist, or back onto a front end alignment rack.

3. Verify the curb position ride height is within specifications with the vehicle unloaded, and all of the tires inflated to their normal operating pressures.

4. Rotate the transmission output yoke until vertical. This will simplify taking measurements.

2. Using the special tool, measure the slope of the components. Record the measurements and the direction of the component's slope.

Example for Calculating Operating Angles

Item Description

1 Output yoke slope

2 Driveshaft slope

3 The driveshaft slope minus the output yoke slope equals the transmission/driveshaft operating angle

4 Pinion flange slope

5 The driveshaft slope minus the pinion flange slope equals the driveshaft/axle operating angle

3. Calculate the difference in the slope of the components to determine the U-joint operating angle.

• When two connected components slope in the same direction, subtract the smaller number from the largest to find the U-joint operating angle. When two connected components slope in the opposite direction, add the measurements to find the U-joint operating angle.

• The U-joint operating angle is the angle formed by two yokes connected by a cross and bearing kit. Ideally, the operating angles on each end of the driveshaft must:

� be equal or within one degree of each other. � have a three degree maximum operating angle. � have at least one-half of one degree continuous operating angle.

An incorrect driveline (pinion) angle can often be detected by the driving condition in which the vibration occurs.

• A vibration during coast-down from 72 to 56 km/h (45 to 35 mph) is often caused by an excessive U-joint angle at the axle (pinion nose downward).

• A vibration during acceleration, from 56 to 72 km/h (35 to 45 mph) may indicate an excessive U-joint angle at the axle (pinion nose upward).

If the tires and driveline angle are not the cause, perform the NVH tests to determine whether the concern is caused by a condition in the axle. For additional information, refer to Section 100-04.

Universal Joint (U-Joint) Wear

Place the vehicle on a frame hoist and rotate the driveshaft by hand. Check for rough operation or seized U-joints. Install a new U-joint if it shows signs of seizure, excessive wear, or incorrect seating. For additional information, refer to Section 205-01.

Drive Pinion Stem and Pinion Flange

Check the pinion flange runout when all other checks have failed to show the cause of vibration.

One cause of excessive pinion flange runout is incorrect installation of the axle drive pinion seal. Check to see if the spring on the seal lip has been dislodged before installing a new differential ring gear and pinion.

Coupling Shaft/Center Bearing Alignment

Vehicle noise and vibration can be caused by a dislodged or failed driveshaft center bearing support rubber insulator, a contaminated driveshaft center bearing support (4800) or excessive compression of the rubber insulator. For additional information, refer to Section 205-01.

Bearing Shimming

Drive-away shudder is the predominant symptom associated with driveline angles condition on vehicles with two-piece driveshafts. Drive-away shudder can usually be corrected by shimming down the driveshaft center bearing bracket. For additional information, refer to Section 205-01.

If the drive-away shudder cannot be corrected by shimming down the driveshaft center bearing bracket, check the driveline angles as described in this section.

Non-Axle Noise

There are several components, which when subject to certain conditions, can produce sound similar to axle noise. These components are the exhaust, the tires, roof racks, the power steering pump, auxiliary fluid coolers and the trim mouldings.

• The pitch of the exhaust may sound like gear whine. • Tires — especially snow tires — can have a high-pitched tread whine or roar similar to

gear noise. Radial tires, to some degree, have this characteristic. Any non-standard tire with an unusual tread construction may also emit a roar or whine-type noise.

• Trim, grille, and mouldings can also cause whistling or whining noises.

Make sure that none of these are the cause of the noise before proceeding with axle teardown and diagnosis.

Axle Noise

NOTE: Before disassembling the axle to diagnose and correct gear noise, eliminate the tires, exhaust, trim items, roof racks, axle shafts (4234) and wheel bearings as possible causes.

The noises described as follows usually have specific causes that can be diagnosed by observation as the unit is disassembled. The initial clues are the type of noise heard during the road test.

Gear Howl and Whine

Howling or whining of the differential ring gear and pinion is due to an incorrect gear pattern, gear damage or incorrect bearing preload.

Bearing Whine

Bearing whine is a high-pitched sound similar to a whistle. It is usually caused by worn/damaged pinion bearings, which are operating at driveshaft speed. Bearing noise occurs at all driving speeds. This distinguishes it from gear whine which usually comes and goes as speed changes.

As noted, pinion bearings make a high-pitched, whistling noise, usually at all speeds. If however, there is only one pinion bearing that is worn/damaged, the noise may vary in different driving phases. Do not install new pinion bearings unless bearings are scored or damaged or there is a specific pinion bearing noise. A worn/damaged bearing will normally be obvious at disassembly. Examine the large end of the rollers for wear. If the pinion bearings original blend radius has worn to a sharp edge, install a new pinion bearing.

NOTE: A low-pitched rumble normally associated with a worn/damaged wheel bearing can be caused by the exterior luggage rack or tires.

A wheel bearing noise can be mistaken for a pinion bearing noise. Check the wheel bearing for a spalled cup, and spalled/damaged rollers. Install a new wheel bearing and cup if any of these concerns are detected.

Chuckle

Chuckle that occurs on the coast driving phase is usually caused by excessive clearance between the differential gear hub and the differential case bore.

Damage to a gear tooth on the coast side can cause a noise identical to a chuckle. A very small tooth nick or ridge on the edge of a tooth can cause the noise.

Clean the gear tooth nick or ridge with a small grinding wheel. If the damaged area is larger than 3.2 mm (1/8 inch), install a new gearset.

To check the differential ring gear and pinion, remove as much lubricant as possible from the gears with clean solvent. Wipe the gears dry or blow them dry with compressed air. Look for scored or damaged teeth. Also look for cracks or other damage.

If either gear is scored or damaged badly, install a new differential ring gear and pinion.

If metal has broken loose, the differential housing must be cleaned to remove particles that will cause damage. At this time, any other damaged parts in the differential housing must also be discarded and new parts installed.

Knock

Knock, which can occur on all driving phases, has several causes including damaged teeth or gearset.

A gear tooth damaged on the drive side is a common cause of the knock. This can usually be corrected by grinding the damaged area.

Clunk

Clunk is a metallic noise heard when the automatic transmission is engaged in REVERSE or DRIVE. The noise may also occur when throttle is applied or released. It is caused by backlash somewhere in the driveline or loose suspension components; it is felt or heard in the axle. For additional information, refer to Total Backlash Check in this section.

Additionally, clunk may be heard upon initial drive-away. This occurs as engine torque shifts vehicle weight, forcing changes in driveline angles, preventing the driveshaft slip-yoke from sliding on the output shaft. To correct for this condition, lubricate the slip-yoke splines. For additional information, refer to Section 205-01.

Total Backlash Check


2. Remove the driveshaft. For additional information, refer to Section 205-01.

3. Install the special tool. • Clamp a rigid bar or pipe to the tool. Clamp the other end of the bar or pipe to the

frame or a body member in order to prevent movement of the pinion flange.

4. Lower the vehicle so that one rear wheel is resting on a wheel chock to prevent it from turning. The other rear wheel will be used to measure total rear axle backlash.

5. Rotate the free wheel slowly, by hand, until the feeling of driving the rear axle is encountered. Place a mark on the side of the tire, 305 mm (12 inches) from the center of the wheel, with a crayon or chalk.

6. While holding the crayon or chalk against the tire, rotate the wheel slowly in the opposite direction until the feeling of driving the rear axle is encountered again.

7. Measure the length of the crayon or chalk mark on the tire. • If the length of the mark is 25.4 mm (1 inch) or less, the rear axle backlash is

within allowable limits. • If the chalk mark is greater than 25.4 mm (1 inch), check for these conditions:

� Elongation of the differential pinion shaft and holes in the differential case (4204).

� Missing differential pinion thrust washer (4230) or differential side gear thrust washer (4228).

� Galling of the differential pinion shaft (4211) and bore. � Excessive ring gear and pinion backlash. Follow the procedure for the type

of rear axle to check backlash.

Bearing Rumble

Bearing rumble sounds like marbles being tumbled. This condition is usually caused by worn/damaged wheel bearing. The lower pitch is because the wheel bearing turns at only about one-third of the driveshaft speed. Wheel bearing noise also may be high-pitched, similar to gear noise, but will be evident in all four driving modes.

Analysis of Inoperative Conditions

If the axle does not operate, one of the following may be the cause.

Broken Welds

If the differential housing welds are completely broken, install a new differential housing.

Wheel Bearing Wear/Damage

Because of the severe loads they must handle, new wheel bearings may need to be installed at high mileage. If a wheel bearing fails at low mileage, it is often caused by overloading.

Axle Lock Up

Lock up or seizure of the axle shaft usually indicates inadequate lubrication. Without enough lubricant, the heated parts get soft and may eventually weld together. Check for lubricant leaks after repair.

Symptom Chart

Symptom Chart


• Excessive Rear/Front Axle Noise

• Rear/front axle. • CARRY OUT the NVH tests to determine whether the noise is a NVH concern caused by a condition in the rear/front axle. REFER to Section 100-04.

• Wheel bearing. • INSPECT and INSTALL new wheel bearings as necessary.

• Loud Clunk in the Driveline When Shifting from Reverse to Forward

• High idle speed. • REFER to Powertrain Control/Emissions Diagnosis (PC/ED) manual.

• Engine mounts. • INSPECT and REPAIR as necessary.

• Driveshaft components.

• REFER to Universal Joint (U-joint) Inspection under Inspection and Verification in this section. REPAIR as necessary.

• Rear axle shafts / • REMOVE, INSPECT and

differential. REPAIR as necessary.


• INSPECT, REPAIR as necessary.

• Backlash in the axle or the transmission.

• CARRY OUT Total Backlash Check in this section. REPAIR as necessary.

• Lubrication. • ADD lubricant as necessary.

• Driveline Clunk as the Vehicle Starts to Move Following a Stop

• Rear spring U-bolts.

• TIGHTEN the U-bolts to specification.

• Output driveshaft and coupling shaft splines.

• REMOVE the driveshaft from the vehicle. CLEAN the male splines and INSPECT for worn or galled splines. REPAIR as necessary.

• Driveshaft slip-yoke splines.

• CLEAN and INSPECT the female splines of the driveshaft slip-yoke for worn or galled condition. REPAIR as necessary.

• Rear Axle Has a High-Pitched Chattering Noise While Turning (Ford Traction-Lok®)

• Lubricant. • ROAD TEST the vehicle. DRIVE in tight circles, 5 clockwise and 5 counterclockwise. If the chatter is still evident, FLUSH and REFILL with the specified rear axle lubricant and dosage of friction modifier additive. REFER to Specifications in this section.

• Differential. • REPAIR as necessary.

• Powr-Lok® Rear Axle Has a Chatter Noise While Turning

• Lubricant • Differential

• Refer to Differential Check — Powr-Lok® Road Test (Dana) in this section.

• Ford Traction-Lok® Does Not Work in Snow, Mud or on Ice

• Differential. • CARRY OUT the Differential Check — Ford Traction-Lok® Road Test in this section. REPAIR as necessary.

• Clicking, Popping, or Grinding Noises While Turning

• Wheel bearings. • REFER to Section 204-01B (4x4) or Section 206-03 (4x2).

• Brake components.

• REFER to Section 206-00.





• Vibration at Highway Speeds

• Out-of-balance wheels or tires.

• BALANCE wheels and tires, or INSTALL new tires as necessary.

• Out-of-round tires.


• Shudder, Vibration During Acceleration

• Axle assembly mispositioned.

• CHECK the axle mounts for damage and wear. REPAIR as necessary.

• Front suspension • CHECK for worn suspension bushings and

components. damaged components. REPAIR as necessary.

• Driveline angles out of specification.

• CHECK the driveline angles.

• Rear spring U-bolt.

• TIGHTEN the U-bolt.

• Binding, damaged, or galled splines on driveshaft slip-yoke.

• CHECK the transmission for correct lubricant. CLEAN and lap the splines. LUBRICATE the splines with Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.

• U-joints binding or seized.


• Driveline Vibration

• U-joint. • INSPECT and INSTALL new universal joints (4249) as necessary. REFER to Section 205-01.

• Pinion flange runout.

• REFER to Driveline Vibration in this section.

• Driveshaft out of balance.

• REFER to Driveline Vibration in this section.

• Driveshaft runout. • REFER to Driveline Vibration in this section.

• Lateral and radial tire and wheel runout.


• Driveline angles out of

• CORRECT as necessary.

specification.

• Splines on driveshaft slip yoke (4841).

• CHECK the transmission for correct lubricant. CLEAN and lap the splines. LUBRICATE the splines with Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.

• Loose driveshaft–to–pinion flange retainers.

• TIGHTEN to specifications. REFER to Section 205-01.

• Noise Is the Same on Drive or Coast

• Road. • Normal condition.

• Tire(s). • BALANCE or INSTALL new tire(s). REFER to Section 204-04.

• Wheel bearing. • INSPECT and, as necessary, ADJUST or INSTALL new wheel bearings.

• Incorrect driveline angles or phasing.

• CORRECT as necessary.

• Lubricant Leaking from the Pinion Seal, Axle Shaft Oil Seals (3254)

• Vent. • CLEAN the differential housing vent.

• Damage in the seal contact area or dust slinger on the pinion flange dust shield.

• INSTALL a new pinion flange and pinion seal if damage is found.

• Noise Tone Lowers as the Vehicle Speed is Lowered

• Tire(s). • BALANCE or INSTALL new tire(s). REFER to Section 204-04.

• Similar Noise Is Produced with the Vehicle Standing and Driving

• Engine. • REFER to Section 303-00.


• Noise Most Pronounced While Turning

• Differential side gears and pinion gears.

• For conventional and Ford Traction-Lok® differentials, INSTALL new gears. The Tractech® Truetrac® differential is non-repairable. DISCARD the entire assembly if it is worn/damaged.

• Drive Noise, Coast Noise or Float Noise

• Wheel/axle shaft bearings or differential side bearings.

• INSPECT and, as necessary, ADJUST or INSTALL new bearings.

• Differential ring gear and pinion.

• CHECK the differential ring gear and pinion. ADJUST or INSTALL a new differential ring gear and pinion.

Component Tests

Driveline Vibration

NOTE: An analysis of driveline vibration can also be conducted using the Electronic Vibration Analyzer and following the manufacturer's directions.

Driveline vibration exhibits a higher frequency and lower amplitude than does high-speed shake. Driveline vibration is directly related to the speed of the vehicle and is usually noticed at various speed ranges. Driveline vibration can be perceived as a tremor in the floor pan or is heard as a rumble, hum, or boom. Driveline vibration can exist in all drive modes, but may exhibit different symptoms depending upon whether the vehicle is accelerating, decelerating, floating, or coasting. Check the driveline angles if the vibration is particularly noticeable during acceleration or deceleration, especially at lower speeds. Driveline vibration can be duplicated by supporting the axle upon a hoist or upon jack stands, though the brakes may need to be applied lightly in order to simulate road resistance.

1. Raise the vehicle promptly after road testing. Use twin-post hoist or jack stands to prevent tire flat-spotting. Engage the drivetrain and accelerate to the observed road test speed to verify the presence of the vibration. If the vibration is not evident, check the non-driving wheels with a wheel balancer to rule out imbalance as a possible cause. If necessary, balance the non-driving wheels and repeat the road test. If the vibration is still evident, proceed to Step 2.

2. Mark the relative position of the drive wheels to the wheel lugs. Remove the wheels. Install all the wheel nuts in the reversed position (wheel nuts can be installed in their normal orientation on axles with dual rear wheels) and repeat the road speed acceleration. If the vibration is gone, refer to the tire and wheel runout procedure in Section 204-04. If the vibration persists, proceed to Step 3.

3. Inspect the driveshaft(s) (for signs of physical damage, missing balance weight, undercoating, incorrect seating, wear and binding universal joints [4635]). Clean the driveshaft and install new universal joints or a driveshaft if damaged. Check the index marks (paint spots) on the rear of the driveshaft and pinion flange. If these marks are more than one quarter turn apart, disconnect the driveshaft and re-index it to align the marks as closely as possible. After any corrections are made, recheck for vibration at the road test speed. If the vibration is gone, reinstall the wheels and road test. If the vibration persists, proceed to Step 4.

4. Raise the vehicle on a hoist and remove the wheels. Rotate the driveshaft by turning the axle and measure the runout at the front, the center, and the rear of the driveshaft with the indicator. If the runout exceeds 0.89 mm (0.035 inch) at the front or center, install a new driveshaft. If the front and center are within this limit, but the rear runout is not, mark the rear runout high point and proceed to Step 5. If the runout is within the limits at all points, proceed to Step 7.

5. NOTE: Check the U-joints during re-indexing. If a U-joint feels stiff or gritty, install new U-joints.

Scribe alignment marks on the driveshaft and the pinion flange. Disconnect the driveshaft, rotate it one half turn, and reconnect it. Circular pinion flanges can be turned in one quarter increments to fine tune the runout condition; half-round pinion flanges are limited to two positions. Check the runout at the rear of the driveshaft. If it is still over 0.89 mm (0.035 inch), mark the high point and proceed to Step 6. If the runout is no longer excessive, check for vibration at the road test speed. If vibration is still present, re-index the driveshaft slip yoke on the transmission output shaft one half turn and road test the vehicle. If the vibration persists, proceed to Step 7.

6. Excessive driveshaft runout may originate in the driveshaft itself or in the pinion flange. To determine which, compare the two high points marked in Steps 4 and 5. If the marks are close together, within about 25 mm (1 inch), install a new driveshaft and road test the vehicle.

If the marks are on opposite sides of the driveshaft, the pinion flange is responsible for the vibration.

When installing a new pinion flange, the driveshaft runout must not exceed 0.89 mm (0.035 inch). When runout is within limits, recheck for vibration at road speed. If vibration persists, balance the driveshaft.

7. To balance the driveshaft, install one or two hose clamps on the driveshaft, near the rear. Position of the hose clamp head(s) can be determined by trial-and-error.

8. Mark the rear of the driveshaft into four approximately equal sectors and number the marks 1 through 4. Install a hose clamp on the driveshaft with its head at position No. 1.

Check for vibration at road speed. Recheck with the clamp at each of the other positions to find the position that shows minimum vibration. If two adjacent positions show equal improvement, position the clamp head between them.

9. If the vibration persists, add a second clamp at the same position and recheck for vibration.

If no improvement is noted, rotate the clamps in opposite directions, equal distances from the best position determined in Step 8. Separate the clamp heads about 13 mm (1/2 inch) and recheck for vibration at the road speed.

Repeat the process with increasing separation until the best combination is found or the vibration is reduced to an acceptable level.

10. Install the wheels and road test (vibration noticeable on the hoist may not be evident during the road test). If the vibration is still not acceptable, install a new axle driveline vibration damper first, if so equipped. If the vibration is still not acceptable, refer to Section 205-02A, Section 205-02B or Section 205-02D for differential case and ring gear runout checks.

Runout Check — Circular Pinion Flange

CAUTION: This operation disturbs the pinion bearing preload. Pinion bearing preload must be reset if the pinion nut has been loosened or removed for pinion flange reindexing or if a new pinion flange was installed.

1. Raise the vehicle on a twin-post hoist that supports the rear axle.


3. Check the pinion flange for damage.

4. Position the special tool on the pinion flange.

5. Position the special tool onto the Companion Flange Runout Gauge.

6. Align the holes on the clamp plate with the holes in the pinion flange and install the bolts. Snug the bolts evenly.

7. Position the special tool as shown. Turn the Companion Flange Runout Gauge, and locate and mark the high spot on the pinion flange with yellow paint.

If the flange runout exceeds 0.25 mm (0.010 inch), remove the pinion flange, reindex the flange one half turn on the pinion, and reinstall it.

8. Check the runout again. If necessary, rotate the flange until an acceptable runout is obtained. If the flange runout is still more than 0.25 mm (0.010 inch), install a new pinion flange.

9. If excessive runout is still evident after installing the new pinion flange, install a new ring and pinion. Repeat the above checks until the runout is within specifications.

10. Install the driveshaft. For additional information, refer to Section 205-01.

Runout Check — Half-Round Companion Flange

CAUTION: Pinion bearing preload must be reset if the pinion nut has been loosened or removed for pinion flange reindexing or replacement.

1. Raise the vehicle on a twin-post hoist that supports the rear axle.


3. Check the pinion flange for damage.

4. Insert the correct size special tool.

5. Position the special tool on the pinion flange.

6. Align the holes on the gauge with the holes in the pinion flange and install the bolts and nuts.

7. NOTE: Accurate tool setup will result in accurate final readings.

Position the special tool as shown. Adjust and lightly tighten the mounting bolts and nuts so the gauge runout is 0.254 mm (0.010 inch) or less.

8. Position the special tool on the edge of the gauge. Turn the Companion Flange Runout Gauge, and locate and mark the high spot on the pinion flange with yellow paint.

If the flange runout exceeds 0.25 mm (0.010 inch), remove the pinion flange, reindex the flange one-half turn on the pinion, and reinstall it.

9. Check the runout again. If necessary, reindex the flange until an acceptable runout is obtained. If the flange runout is still more than 0.25 mm (0.010 inch), install a new pinion flange.

10. If excessive runout is still evident after installing the new pinion flange, install a new ring and pinion. Repeat the above checks until the runout is within specifications.


Differential Check — Ford Traction-Lok® Road Test (Ford)

1. Place one wheel on a dry surface and the other wheel on ice, mud or snow.

2. Gradually open the throttle to obtain maximum traction prior to break away. The ability to move the vehicle demonstrates correct performance of a Traction-Lok® rear axle assembly (4006).

3. When starting with one wheel on an excessively slippery surface, a slight application of the parking brake may be necessary to help energize the Traction-Lok® feature of the differential. Release the brake when traction is established. Use light throttle on starting to provide maximum traction.

4. If, with unequal traction, both wheels slip, the limited slip rear axle has done all it can possibly do.

5. In extreme cases of differences in traction, the wheel with the least traction may spin after the Traction-Lok® has transferred as much torque as possible to the non-slipping wheel.

Differential Check — Tractech® Truetrac®

1. Shift the transmission into NEUTRAL.


3. Spin either rear wheel. • Both wheels must spin with a fluid motion. Any feeling of gripping and

release/roughness indicates that further inspection of the axle assembly is necessary. For additional information about axle disassembly and inspection, refer to Section 205-02A or Section 205-02B.

4. Shift the transmission into gear.

5. Spin either rear wheel. • The other wheel must spin with a fluid motion in the opposite direction and at the

same speed of the wheel being spun. Any feeling of gripping and release/roughness indicates that further inspection of the axle assembly is necessary. For additional information about axle disassembly and inspection, refer to Section 205-02A or Section 205-02B.

Differential Check — Powr-Lok® Road Test (Dana)

1. Drive the vehicle for at least ten miles to warm up the axle lubricant. • More miles may be necessary depending on the outside temperature.

2. Drive the vehicle in a tight circle for five minutes and then in the opposite direction for another five minutes.

3. Make a minimum of ten figure eight turns.

4. If chatter is still present, drain and refill the axle with the specified type and amount of lubricant and friction modifier. For additional information, refer to Specifications in this section.

5. Perform the road test again. • There might be a slight chatter. If the chatter persists after 160 km (100 miles) of

vehicle operation, install a new differential.

Tooth Contact Pattern Check — Gearset, Dana S135

1. CAUTION: If reusing the differential ring gear and pinion, measure and record the backlash before disassembly. Re-assembling the differential ring gear and pinion to the recorded backlash will match the established wear patterns. Hand rolled patterns will cover less area than the established patterns.

Paint one quarter of both the drive and the coast side of the differential ring gear with marking compound.

2. While applying a load, rotate the differential ring gear one complete revolution.

Correct Contact Pattern — Single Index Lightly Loaded

Correct Contact Pattern — Single Index Heavily Loaded

3. Verify the contact pattern is correct. • Tooth contact pattern can move only by adjusting backlash. Tooth contact pattern

can move only in the direction of heal-to-toe, and toe-to-heel. Depth of the tooth contact pattern is not adjustable. Contact Spicer Service at 1-800-666-8688 for assistance if you are unable to establish an acceptable tooth contact pattern within the limits of backlash.

Tooth Contact Pattern Check — Gearset, Except Dana S135

1. To check the gear tooth contact, paint the gear teeth with the special marking compound. A mixture that is too wet will run and smear; a mixture that is too dry cannot be pressed out from between the teeth.

2. Use a box wrench on the ring gear bolts as a lever to rotate the differential ring gear several complete revolutions in both directions or until a clear tooth contact pattern is obtained.

3. Certain types of gear tooth contact patterns on the differential ring gear indicate incorrect adjustment. Incorrect adjustment can be corrected by readjusting the differential ring gear or the pinion.

Contact Pattern Location — Except Dana S135

In general, desirable ring gear tooth patterns must have the following characteristics:

• Drive pattern on the drive side differential ring gear well centered on the tooth. • Coast pattern on the coast side differential ring gear well centered on the tooth. • Clearance between the pattern and the top of the tooth. • No hard lines where the pressure is high.

Acceptable differential ring gear tooth patterns for all axles.

Correct backlash with a thinner pinion position shim required.

Correct backlash with a thicker pinion position shim required.

Correct pinion position shim that requires a decrease in backlash.

Correct pinion position shim that requires an increase in backlash.




Axle Housing Casting Porosity (Holes in Casting) Repair

NOTE: Do not disassemble the carrier. Make repairs on the outside of the axle.

NOTE: Casting porosity is a condition where occasionally gas bubbles will form during the casting process leaving small pockets in the metal that may cause the axle housing to show signs of dampness.

1. To fill small pockets, peen in a small amount of body lead.

2. Seal the pocket. • Use Devcon Aluminum Liquid F2 or equivalent meeting Ford specification M-

3D35A(E).

3. To fill large pockets, drill and tap a shallow hole for a small setscrew. Install the setscrew and seal it.

• Use Devcon Aluminum Liquid F2 or equivalent meeting Ford specification M-3D35A(E).

SECTION 205-01:

Driveshaft

SPECIFICATIONS


Driveshaft

Universal Joints


Driveshaft

GENERAL PROCEDURES

Indexing

Runout and Balance


Driveshaft—Front

Driveshaft—Rear, One-Piece, 4x2 With 137-Inch and 141-Inch Wheel Base

Driveshaft—Rear, One-Piece, 4x4 With 137-, 141- and 142-Inch Wheel Base

Driveshaft—Rear, Two-Piece

Driveshaft—Rear, Three-Piece, F-450, F-550

Driveshaft—Rear, Three-Piece, Motorhome

DISASSEMBLY AND ASSEMBLY

Center Bearing

Universal Joint—Single Cardan

Universal Joint—Double Cardan

Driveshaft Slip Yoke

SECTION 205-01: Driveshaft 1999 F-Super Duty 250-550 Workshop Manual



Item Specification




Driveshaft to transfer case bolts, front 102 76

Driveshaft to transfer case bolts, rear 102 76

Driveshaft to front axle bolts 35 26

Driveshaft to rear axle bolts (except Motorhome) 35 26

Driveshaft to parking brake drum bolts 150 111

Driveshaft center bearing bolts (except Motorhome) 63 47

Driveshaft to coupling shaft (except Motorhome) 35 26

Driveshaft to manual transmission flange 102 76

Driveshaft to coupling shaft (Motorhome) 102 76

Driveshaft to rear axle bolts (Motorhome) 74.5 55

Driveshaft center bearing bolts (Motorhome) 90 66

Reverse slip driveshaft flange nut 407 300



Driveshaft

Driveshaft — Front


1 4A376 Driveshaft

2 4782 Driveshaft Centering Socket Yoke

3 — Snap Ring (Part of 4635)

4 4635 Universal Joint (U-Joint)

5 4784 Driveshaft Center Yoke

6 4K277 Driveshaft Slip Yoke Boot Clamp

7 4421 Driveshaft Slip Yoke Boot

8 4841 Driveshaft Slip Yoke

Driveshaft — Rear, One-Piece 4x2 with 137- and 141-Inch Wheel Base


1 4851 Driveshaft Rear Axle Flange


3 4A254 U-Joint Retainer

4 4602 Driveshaft


Driveshaft — Rear, One-Piece 4x4 with 141-Inch Wheel Base


1 4602 Driveshaft






Driveshaft — Rear, One-Piece 4x4 with 137- and 142-Inch Wheel Base


1 4602 Driveshaft

2 4782 Driveshaft Centering Socket Yoke



5 4784 Driveshaft Center Yoke

6 — Spring (Part of 4A376)




Driveshaft — Rear, Two-Piece, All Models Except XLT and Lariat 4x2 with 142-Inch Wheel Base and 156- and 158-Inch Wheel Base




3 — Bearing (Part of 4635)

4 — Seal (Part of 4635)

5 — Spider (Part of 4635)

6 4K145 Driveshaft Assy

7 4K277 Driveshaft Slip Yoke Boot Clamp (Small)


9 4K277 Driveshaft Slip Yoke Boot Clamp (Large)


11 — Vehicles with Manual Transmission

12 — Vehicles with Automatic Transmission

13 4800 Center Bearing Assy

14 — Rubber Insulator (Part of 4800)

15 — Center Bearing (Part of 4800)

16 — Bearing Retainer Ring (Part of 4800)

17 4A499 Driveshaft Center Bearing Bracket

Driveshaft — Rear, Two-Piece, XLT and Lariat Models 4x2 with 142-Inch Wheel Base and 156- and 158-Inch Wheel Base


7 4851 Driveshaft Yoke

8 — Vehicles with Manual Transmissions

9 — Vehicles with Automatic Transmissions



12 — Center Bearing (Part of 4800)







Driveshaft — Rear, Three-Piece

Item Part

Number Description



3 — Center Bearing

(Part of 4800)









12 4K185 Driveshaft Assy — Rear

13 — Vehicles with Automatic Transmission

14 — Vehicles with Manual Transmission or Motorhome

15 4817 Driveshaft — Front

16 4851 Driveshaft Yoke





The driveshaft (4602) is a tubular shaft used to transfer torque from the engine, through the transmission to the ring and pinion in the rear axle, which transmits the torque to the wheels. Driveshafts differ in length, diameter and type to accommodate various wheelbase, GVW ratings and powertrain combinations.

The driveshaft has half round end yokes with bolt and strap attachment at all front and rear axle ends and bolt attachments at the transfer case and manual transmission outputs.



Universal Joints


1 4635 Universal joint (U-joint)

2 — Grease seal (part of 4635)

3 — 32 needle rollers (part of 4635)

4 — Thrust washer (part of 4635)

5 — Bearing cup (part of 4635)

6 — Spider (part of 4635)

Universal joints have the following:

• A lubed-for-life design. • Equipped with nylon thrust washers located at the base of each bearing cup, which

control end play, positions the needle bearings and improves grease movement. • Size 1350 for E-150-350, size 1410 for E-450, and size 1480 for E-550.

Universal Joint (U-Joint) Identification Chart

Series Diameter 1 (Spider outer diameter with bearing Diameter 2 (bearing cup outer

cups fully seated) diameter)

1350 91.9 (3.62) 30.2 (1.19)

1410 106.4 (4.19) 30.2 (1.19)

1480 106.4 (4.19) 35.1 (1.38)



Driveshaft




Indexing




Runout and Balance




Driveshaft—Front

Removal


2. Index-mark the front driveshaft to the front axle flange and at the transfer case flange.

3. Remove and discard the fasteners. 1. Remove and discard the bolts.

2. Remove and discard the U-joint retainers.

4. Remove and discard the four bolts.

5. NOTE: Wrap electrical tape around the bearing cups to prevent them from falling off the U-joint spider.

Remove the front driveshaft.

• Compress and separate the front driveshaft from the front axle, then separate the driveshaft from the transfer case.

Installation

1. NOTE: Install the front driveshaft with the index marks aligned.

NOTE: An extension must be used to tighten the driveshaft to transfer case bolts. Extensions change the calibration of the torque wrench. Use the torque wrench manual to calculate the correct settings.

NOTE: Install new bolts and retainers.




Driveshaft—Rear, One-Piece, 4x2 With 137-Inch and 141-Inch Wheel Base

Removal


2. Index-mark the driveshaft (4602) at the axle flange.

3. Disconnect the driveshaft from the axle flange. 1. Remove and discard the bolts.


4. NOTE: Index-mark the output shaft to the slip yoke.

For vehicles equipped with an automatic transmission, lower the driveshaft and slide the driveshaft rearward off the transmission output shaft.

• Plug the extension housing to prevent fluid loss.

5. NOTE: Index-mark the driveshaft to the transmission flange.

For vehicles equipped with a manual transmission, remove and discard the bolts.

6. Remove the driveshaft.

Installation

1. NOTE: Inspect the transmission and axle seals for damage. Install new components as necessary.

NOTE: Lubricate the slip yoke spline with Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.


NOTE: Install the driveshaft so that the index marks made before removal are aligned or the yellow mark on the driveshaft tube is in line with the yellow mark on the rear axle flange.




Driveshaft—Rear, One-Piece, 4x4 With 137-, 141- and 142-Inch Wheel Base

Removal


2. Index-mark the rear driveshaft to the rear axle flange and at the transfer case flange.

3. Remove and discard the fasteners. 1. Remove and discard the bolts.


4. Remove and discard the four bolts.

5. NOTE: Wrap electrical tape around the bearing cups to prevent them from falling off the U-joint spider.

Remove the rear driveshaft.

• Compress and separate the rear driveshaft from the rear axle, then separate the driveshaft from the transfer case.

Installation

1. NOTE: Install the rear driveshaft with the index marks aligned.





Driveshaft—Rear, Two-Piece



2. Index-mark the driveshaft at the axle flange.



• Using mechanics wire, support the driveshaft.

4. NOTE: Index-mark the driveshaft to transfer case or transmission flange.

For four-wheel drive vehicles, or vehicles equipped with a manual transmission, disconnect the driveshaft from the transfer case or transmission.

• Remove and discard the bolts.


5. For vehicles equipped with an automatic transmission, index-mark the output shaft to slip yoke.

6. Remove the center bearing support bolts.

7. Remove the driveshaft assembly. • For vehicles equipped with an automatic transmission, lower the driveshaft and

slide the driveshaft rearward off of the transmission output shaft. • Plug the extension housing to prevent fluid loss.

8. Clean grease deposits, dirt and rust from the following: • The driveshaft yoke areas. • All driveshaft components. • Wipe the bearing and rubber insulator of the driveshaft center bearing. Do not

immerse in solvent.

9. Inspect the following: • The driveshaft slip yoke boot for rips or holes. Install a new boot if necessary. • The driveshaft center bearing support for wear or rough action. If roughness or

wear is evident, install a new driveshaft center bearing support. • The center bearing rubber insulator for evidence of hardening, cracking or

deterioration. Install a new insulator if necessary.

10. NOTE: Inspect the transmission, transfer case and axle seals for damage. Install new components as necessary.

NOTE: Lubricate the slip yoke spline with Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.

NOTE: Install the driveshaft so that the index marks made before removal are aligned or the yellow mark on the driveshaft tube is in line with the yellow mark on the rear axle flange.





Driveshaft—Rear, Three-Piece, F-450, F-550

Removal




2. Remove and discard the U-joint retainers. � Using mechanics wire, support the driveshaft.

4. Disconnect the driveshaft from the coupling shaft. 1. Remove and discard the bolts.

2. Remove the U-joint retainers. � Using mechanics wire, support the driveshaft.


6. Remove the rear driveshaft assembly.

7. NOTE: Index-mark the driveshaft to transmission flange (manual transmission) or output shaft to slip yoke (automatic transmission).

For vehicles equipped with a manual transmission, remove and discard the bolts.


9. Remove the front driveshaft. • For vehicles equipped with an automatic transmission, lower the driveshaft and

slide it rearward off the transmission output shaft. • Plug the extension housing to prevent fluid loss.


immerse in solvent.

11. Inspect the following: • The universal joint slip yoke boot for rips or holes. Install a new boot if necessary. • The driveshaft center bearing support for wear or rough action. If roughness or

wear is evident, install a new driveshaft center bearing support. • The center bearing rubber insulator for evidence of hardening, cracking or


Installation

1. For vehicles equipped with a manual transmission, align the index marks and connect the front driveshaft to the transmission. Install the new bolts.

• Hand-tighten only; do not tighten at this time.

2. For vehicles equipped with an automatic transmission, align the index marks and slide the driveshaft slip yoke onto the output shaft.

3. Position the center support bearing and install the bolts. • Hand-tighten only; do not tighten at this time.

4. Tighten the driveshaft to transmission flange bolts and the driveshaft center bearing bolts.

5. Position the rear driveshaft assembly and install the center support bearing bolts. • Hand-tighten only; do not tighten at this time.

6. Connect the rear driveshaft assembly to the front driveshaft. Install the new retainers and bolts.

7. Connect the rear driveshaft assembly to the rear axle. Install the new retainers and bolts.

8. Tighten the driveshaft center support bearing bolts.



Driveshaft—Rear, Three-Piece, Motorhome

Removal



3. Disconnect the driveshaft (4602) from the axle flange. 1. Remove and discard the bolts.



4. Disconnect the driveshaft from the coupling shaft. 1. Remove and discard the bolts.




6. Remove the rear driveshaft assembly.

7. Remove and discard the bolts.


9. Remove the front driveshaft.


immerse in solvent.

11. Inspect the following: • The universal joint slip yoke boot (4421) for rips or holes. Install a new boot if

necessary. • The driveshaft center bearing support (4800) for wear or rough action. If

roughness or wear is evident, install a new driveshaft center bearing support. • The center bearing rubber insulator for evidence of hardening, cracking or


Installation

1. Connect the front driveshaft (4A376) to the transmission. Install the new bolts. • Hand-tighten only; do not tighten at this time.

2. Position the center support bearing and install the bolts. • Hand-tighten only; do not tighten at this time.

3. Tighten the driveshaft to parking brake drum bolts and the driveshaft center bearing bolts.

4. Position the rear driveshaft assembly and install the center support bearing bolts. • Hand-tighten only; do not tighten at this time.

5. Connect the rear driveshaft assembly to the front driveshaft. Install the new retainers and bolts.

6. Connect the rear driveshaft assembly to the rear axle. Install the new retainers and bolts.

7. Tighten the driveshaft center support bearing bolts.


DISASSEMBLY AND ASSEMBLY Procedure revision date: 01/26/2000

Center Bearing

Disassembly and Assembly

1. CAUTION: Do not clamp the driveshaft in the jaws of a vice or a similar holding fixture.

Place the driveshaft on a suitable workbench.

2. On reverse slip driveshafts, while using a suitable flange holding tool to prevent shaft rotation, remove the flange retaining nut.

3. On reverse slip driveshafts, remove the flange.

4. Remove the rubber insulator surrounding the bearing. 1. Remove the driveshaft center bearing retainer.

2. Remove the driveshaft center bearing bracket.

3. Remove the rubber insulator.

5. Using a suitable press, remove the bearing from the driveshaft.

6. Using a suitable press, remove the dust slinger.

7. NOTE: Clean grease deposits, dirt and rust from the stub shaft.

NOTE: Inspect the stub shaft splines for nicks, gouges, or burrs. Remove with a file or emery cloth.

NOTE: The driveshaft center bearing bracket must be installed with the deep flange rearward.

To assemble, reverse the diassembly procedure.

• Lubricate the stub shaft spline with Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.



Universal Joint—Single Cardan

Special Tool(s)

C-Frame and Screw 205-086 (T74P-4635-C)

Disassembly

1. CAUTION: Do not clamp the driveshaft (4602) in the jaws of a vice or a similar holding fixture.


2. Index mark the driveshaft and driveshaft components.

3. Clamp the C-Frame and Screw in a vise.

4. Remove the snap rings.

5. NOTE: If the bearing cup cannot be pressed all the way out, remove it with gripping pliers.

Remove the driveshaft slip yoke (4841).

1. Position the driveshaft into the C-Frame and Screw.

2. Press out a bearing cup.

3. Rotate the driveshaft 180 degrees.

4. Press on the spider to remove the bearing cup from the opposite side.

5. Remove the driveshaft slip yoke.

6. Remove the remaining bearing cups and spider.

7. Clean the driveshaft yoke area at each end of the driveshaft. • Inspect the driveshaft and driveshaft components for wear or damage.

Assembly

NOTE: Universal joint service kits are to be installed as complete assemblies only. Do not use components from other universal joints.

1. Install a new bearing cup. 1. Start a new bearing cup into the driveshaft yoke.

2. Position a new spider in the driveshaft yoke.

3. Install the driveshaft into the C-Frame and Screw.

4. Press the bearing cup just below the snap ring groove.

2. NOTE: Use the yellow snap rings supplied in the universal kit. If difficulty is encountered installing the yellow snap rings, install the black snap rings also supplied in the kit.

Remove the driveshaft from the tool and install the snap ring.

3. Repeat Steps 1 and 2 for the opposite side of the driveshaft yoke.

4. Install a new bearing cup. 1. Position a new bearing cup in the driveshaft slip yoke.

2. Install the driveshaft into the C-Frame and Screw.

3. Press the bearing cup just below the snap ring groove.

5. NOTE: Use the yellow snap rings supplied in the universal kit. If difficulty is encountered installing the yellow snap rings, install the black snap rings also supplied in the kit.

Remove the driveshaft from the tool and install the snap ring.

6. Repeat Steps 4 and 5 for the opposite side.

7. NOTE: Do not strike the bearings. If binding, strike the yoke with a brass or plastic hammer to seat the bearing cups.

Check the U-joint for freedom of movement.



Universal Joint—Double Cardan

Special Tool(s)

C-Frame and Screw 205-086 (T74P-4635-C)

Differential Bearing Cone Remover 205-116 (T77F-4220-B1)

Step Plate 8059

Disassembly

1. CAUTION: Do not clamp the driveshaft (4602) in the jaws of a vice or a similar holding fixture.


2. Index mark the double cardan yokes.

3. Remove the snap rings.

4. Position the C-Frame and Screw in a swivel base vise.

5. CAUTION: Do not force the tool when the U-joint bottoms out as the center bearing shield may be damaged.

Using the C-Frame and Screw, press the driveshaft center yoke bearing cups through the opposite side.

• Alternate the pressure between the U-joints.

6. Remove opposing bearing cups with gripping pliers.

7. Rotate the double cardan 180 degrees, and press the bearing cups through on the opposite side.

8. Remove the bearing cups with gripping pliers.

9. Remove remaining bearing cups and spiders, and on the one-piece rear driveshaft, the spring.

• The centering ball on the driveshaft end yoke is not serviceable. If the centering ball is damaged, install a new driveshaft.

Assembly

1. Position the spider in the driveshaft end yoke, and position the bearing cup on the spider trunnion.

2. Using the C-Frame and Screw, press the bearing cup until the opposite bearing cup can be positioned on the spider trunnion.

3. NOTE: Align the index marks made during disassembly.

Position the driveshaft center yoke on the spider, and using the C-Frame and Screw, press the bearing cups into position.

• Install the snap rings.

4. Apply Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.

5. On the one-piece rear driveshaft, install a new spring.

6. NOTE: Align the index marks made during disassembly.

Position the remaining spider, the centering flange yoke and the bearing cup.

7. Using the C-Frame and Screw, press the bearing cup until the opposite bearing cup can be positioned on the spider trunnion.

8. Position the bearing cup on the spider in the centering flange yoke.

9. Press the bearing cup into position.

10. CAUTION: The final bearing cup will require center ing due to spring pressure.

NOTE: Position the jaws of the Differential Bearing Cone Remover into the driveshaft center yoke bearing cup bores.

Use the Differential Bearing Cone Remover and Step Plate and hand tighten the Differential Bearing Cone Remover to center the spider trunnion in the bore.

11. Install the final bearing cup.

12. NOTE: It may be necessary to tap the yokes with a soft-faced hammer to seat the bearing cups.

Install the remaining snap rings.

13. Move the end yoke through the working angles to ensure freedom of movement.



Driveshaft Slip Yoke

Special Tool(s)

Installer, Constant Velocity Joint Boot Clamp 205-343 (T95P-3514-A)

Installer, Keystone Clamp 211-002 (T63P-9171-A)

Disassembly

1. CAUTION: Do not clamp the driveshaft in the jaws of a vice or a similar holding fixture.


2. Index-mark the driveshaft slip yoke and the stub shaft.

3. Remove the driveshaft slip yoke. 1. Cut and discard the driveshaft slip yoke boot clamps.

2. Separate the driveshaft slip yoke from the stub shaft.

4. Remove and discard the driveshaft slip yoke boot.

5. Check the lubricant for contamination. If the lubricant feels gritty, clean and inspect the stub shaft and driveshaft slip yoke for wear. Install new components as necessary.

Assembly

All driveshafts

1. Fill the driveshaft slip yoke boot with approximately 10 grams (0.36 ounce) of grease. • Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification

ESA-M1C75-B.

2. Position the driveshaft slip yoke boot clamp on the stub shaft.

3. Slide the driveshaft slip yoke boot over the stub shaft, and seat it in the boot groove.

Rear driveshafts

4. Using the special tool, install the driveshaft slip yoke boot clamp.

All driveshafts

5. Install the driveshaft slip yoke. 1. Position the driveshaft slip yoke boot clamp.

2. Pull the driveshaft slip yoke boot toward the stub shaft tube.

3. Lubricate the stub shaft splines. � Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford

specification ESA-M1C75-B.

4. Align the index marks, and install the driveshaft slip yoke.

5. Seat the driveshaft slip yoke boot in the boot groove.

Front driveshaft

6. Remove all excess grease from the slip yoke boot and the slip yoke.

7. Using the special tool, install both driveshaft slip yoke boot clamps. Tighten the tool until the clamp is secure.

Rear driveshafts

8. Remove all excess grease from the slip yoke boot and the slip yoke.

9. Set the driveshaft assembled length to specification. 1. Set the driveshaft assembled length to specification.

� Measure from the stub shaft weld to the U-joint centerline.

2. Bleed the air from the driveshaft slip yoke boot.

3. Position the driveshaft slip yoke boot clamp.

10. Using the special tool, install the driveshaft slip yoke boot clamp.

SECTION 205-02A:

Rear Drive Axle/Differential — Dana 80

SPECIFICATIONS


Rear Drive Axle and Differential



GENERAL PROCEDURES

Differential Case and Pinion Set Up

Differential Case End Play Check

Pinion Ring Gear Variation Number

Ring Gear and Pinion Backlash

IN-VEHICLE REPAIR

Axle Shaft

Axle Assembly

Driveshaft

Drive Pinion Flange

Drive Pinion Seal


Axle Assembly


Differential Case and Ring Gear





Item Specification

Lubricants

SAE 75W-90 Thermally Stable Multi-Purpose Gear Lubricant XY-75W90-QL

WSP-M2C201-A

Additive Friction Modifier C8AZ-19B546-A EST-M2C118-A

Premium Long-Life Grease XG-1-C or -K ESA-M1C75-B

Sealants

Silicone Rubber F7AZ-19554-CA ESB-M4G92-A

Threadlock® and Sealer E0AZ-19554-AA WSK-M2G351-A5

Axle Specifications

Approximate Capacities Axle Model Ford Specification Liters Pint

80 (Conventional and Truetrac® Differentials)

WSP-M2C201-A 4.0 8.5

80 (Trac-Lok®)

WSP-M2C201-A 3.8a 8.0a

a First fill the axle with 0.2365 liters (0.5 pints) of Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A.

Dana Axle Adjustments

Description Specification

Maximum spread of rear axle 0.25 mm (0.010 in)

Backlash between differential ring gear and pinion 0.13-0.20 mm (0.005-0.008 in)

Backlash maximum variation between checkpoints 0.05 mm (0.002 in)

Pinion bearing preload (with new bearings) 2.26-4.53 Nm (20-40 lb-in)

Total (pinion plus differential) preload with new bearings Add 0.7-0.9 Nm (6-8 lb-in)



Pinion shaft lock nut 637 470

Driveshaft bolts 123-149 91-110

Differential bearing cap bolts 108 80

Ring gear bolts — grade 9 298 220

Oil filler plug — 1/4-inch recess drive 27-41 20-31

Differential housing cover bolts (F350) 47 35

Differential housing cover bolts (F450-F550) 61 45

Sensor (ABS) bolt 34-47 26-35





Dana Model 80 Full-Floating Rear Drive Axle

Identification Tag

Item Description

1 Axle ratio

2 Axle assembly number (prefix letters)

3 Axle assembly number (suffix letters)

4 Dana part number

5 Included for models with limited slip differential

Dana Model 80, Full-Floating Rear Axle, Disassembled View

Item Part

Number Description

1 N808133 Bolt

2 4234 Axle shaft

3 1001 Rear wheel gasket

4 2C190 Rear brake anti-lock sensor

5 4067 Drive pinion bearing preload shim

6 4621 Pinion bearing, outer

7 4676 Pinion seal

8 4851 Pinion flange

9 4329 Washer

10 354845 Lock nut

11 4667 Oil slinger

12 4616 Pinion bearing cup, outer

13 4010 Differential housing

14 4628 Pinion bearing cup, inner

15 4630 Pinion bearing, inner

16 4109 Drive pinion position shim

17 4209 Pinion (matched set)

18 4209 Differential ring gear (matched set)

19 — Identification tag (part of 4002)

20 353051 Fill plug

21 4033 Differential housing cover

22 4346 Cover bolt

23 — Brake line clip (part of 4033)

24 355765-S Bearing cap bolt

25 — Bearing cap (part of 4010)

26 4222 Differential bearing cup

27 4K067 Outboard spacer

28 4221 Differential bearing

29 4211 Differential pinion shaft

30 4230 Differential pinion thrust washer

31 4228 Differential side gear thrust washer

32 4236 Differential side gear

33 4215 Differential pinion gear

34 4067 Differential bearing shim (preload/backlash)

35 4558 Rear axle differential ring gear bolt

36 4204 Differential case (conventional)

37 4026 Differential case Trac-Lok® (The Trac-Lok® differential is a non-repairable unit)

38 4B409 Anti-lock speed sensor ring

39 4241 Differential pinion shaft lock pin

40 4026 Differential assembly Truetrac® (The Truetrac® differential is a non-repairable unit)

NOTE: Unless noted, the procedures in this section apply to the conventional differential, Trac-Lok® differential, and Truetrac® differential, though most of the illustrations used in the procedures show the conventional differential.

The Model 80 rear axle features the following:

• a hypoid design differential ring gear and pinion with the centerline of the pinion set below the centerline of the differential ring gear

• full floating axle shafts • an integral-type differential housing consisting of a cast center section with two steel

tubes • a stamped differential housing cover for F-350 DRW • a cast aluminum differential housing cover for F-450 DRW • a conventional differential assembly for F250 • a conventional differential assembly or a Trac-Lok® limited slip differential assembly for

F350 • a conventional differential assembly or a Truetrac® limited slip differential assembly for

F450






SECTION 205-02A: Rear Drive Axle/Differential

— Dana 80 1999 F-Super Duty 250-550

Workshop Manual


Differential Case and Pinion Set Up

Special Tool(s)

Installer, Differential Carrier Bearing 205-D044 (D81T-4221-A) or equivalent

Gauge, Clutch Housing 308-021 (T75L-4201-A)

Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent

Set, Dummy Bearing 205-D048 (D81T-4222-ER) or equivalent

Step Plate 205-D019 (D80L-630-8) or equivalent

Differential Case End Play Check

1. Install the outboard spacers in the side from which they were removed.

2. NOTE: Remove all nicks, burrs, dirt, etc. from the differential case hubs, to allow the bearings to rotate freely.

Place the special tool on the differential case hubs, and position the assembly into the differential housing.

3. NOTE: Use a dial indicator with a minimum travel capability of 5.08 mm (0.200 in).

NOTE: The rear axle uses a combination of differential bearing shims and selective outboard spacers to control differential case end play. The old outboard spacers provide a good starting point when setting end play. However, if additional shimming is necessary, beyond what the hardened differential bearing shims can provide, select and install different thickness outboard spacers.

Mount the special tools as shown. Locate the tip of the Clutch Housing Gauge on a flat surface of one of the bolts.

4. NOTE: Repeat this step and the following step until the same reading appears on the indicator each time. Record the reading. This is the total differential bearing shim thickness necessary, less preload. The final calculation occurs later during assembly.

Force the differential case as far as possible toward the indicator. With force still applied, set the indicator at 0.

5. Force the differential case as far as it will go in the opposite direction. Record the total differential case end play reading.

6. After making sure the reading is correct, remove the special tools and the differential from the differential housing. Do not remove the Master Bearings from the differential case at this time.

Pinion Ring Gear Variation Number

NOTE: If so equipped, install a new pinion shaft oil slinger if bent or mutilated.

NOTE: The differential ring gear and pinion is only available in a matched set. Matching numbers etched on both the differential ring gear and pinion are for verification. If installing a new differential ring gear and pinion, verify these numbers match before proceeding with assembly. The end of the pinion with the etched figures is the "button" end.

NOTE: Use the gear contact pattern method to verify the final pinion position is valid. For additional information, refer to Section 205-00.

1. Shim the pinion as follows: • Etched on the button end of each pinion is a zero (0), or a plus (+) or minus (-)

with a number. This number indicates the best running position for each particular differential ring gear. Shimming behind the inner pinion bearing controls this dimension.

2. If reusing the old differential ring gear and pinion, measure and record the old drive pinion position shim thickness and select a new shim of the same dimension.

• To change the pinion adjustment, shims are available in the thickness of 0.69-1.68 mm (0.027-0.066 in). Measure each shim separately with a micrometer.

3. If installing a new differential ring gear and pinion, notice the (+) or (-) etching on both the old and new pinion, and adjust the new shim thickness to compensate for the

difference of these two figures. If so equipped, include the oil slinger thickness in the total measurement to correctly set pinion depth.

• For example, a pinion etched with m+8 (+3) requires 0.08 mm (0.003 in) less shimming than a pinion etched "0". This means to increase the mounting distance by the amount etched in the pinion, subtract 0.08 mm (0.003 in) from the drive pinion position shim selected for installation. A pinion etched m-8 (-3), requires 0.08 mm (0.003 in) more shimming than a pinion etched "0". In this instance, add 0.08 mm (0.003 in) to the drive pinion position shim selected for installation to decrease the pinion mounting distance by the amount etched in the pinion.

New Pinion Conversion Chart (Metric)

New Pinion Marking (Metric) Old Pinion Marking -10 -8 -5 -3 0 +3 +5 +8 +10

+10 +.20 +.18 +.15 +.13 +.10 +.08 +.05 +.03 0

+8 +.18 +.15 +.13 +.10 +.08 +.05 +.03 0 -0.3

+5 +.15 +.13 +.10 +.08 +.05 +.03 0 -.03 -.05

+3 +.13 +.10 +.08 +.05 +.03 0 -.03 -.05 -.08

0 +.10 +.08 +.05 +.03 0 -.03 -.05 -.08 -.10

-3 +.08 +.05 +.03 0 -.03 -.05 -.08 -.10 -.13

-5 +.05 +.03 0 -.03 -.05 -.08 -.10 -.13 -.15

-8 +.03 0 -.03 -.05 -.08 -.10 -.13 -.15 -.18

-10 0 -.03 -.05 -.08 -.10 -.13 -.15 -.18 -0.20

•

Ring Gear and Pinion Backlash

1. Install the outboard spacers in the side from which they were removed.

2. Place the differential assembly with the special tool in the differential housing.

3. Install the special tools. Locate the tip of the Clutch Housing Gauge on a flat surface of one of the bolts.

4. NOTE: Repeat this step and the following step until the same reading appears on the indicator each time. This is the differential bearing shim thickness necessary between the differential case and the differential bearing on the differential ring gear side of the differential case.

Force the differential case (differential ring gear) away from the drive pinion. With force still applied, set the indicator at 0.

5. Force the differential ring gear into mesh with the pinion, to obtain an indicator reading. Record the reading.

6. Remove the special tools and the differential case from the differential housing.

7. Remove the Master Bearings from the differential case.

8. Place one shim, of the necessary thickness as determined from the previous measurement, on the differential ring gear side of the differential case. If additional shimming is necessary, beyond what the hardened differential bearing shim can provide, select and install a different thickness outboard spacer.

9. Using the special tool, install the differential bearing on the differential ring gear side of the differential case.

10. Determine the correct shim thickness, and place the shim on differential case hub on the drive pinion side.

• To determine the correct shim thickness, first subtract the reading of the previous measurement from the total differential case end play reading obtained under

Differential Case End Play Check in this section. Then, add 0.25 mm (0.010 in) to this amount. This is the correct thickness shim to place on the hub. If additional shimming is necessary, beyond what the hardened differential bearing shim can provide, select and install a different thickness outboard spacer.

11. Using the special tools, install the differential bearing. 1. Place the special tool on the differential bearing to protect it during the

installation of the opposite bearing.

2. Using the special tool, drive the differential bearing onto the hub.



IN-VEHICLE REPAIR Procedure revision date: 01/26/2000

Axle Shaft




Workshop Manual


Axle Assembly

Special Tool(s)

2 Jaw Puller 205-D026 (D80L-1002-L) or equivalent

Alignment Adapter 205-D028 (D80T-4020-R60)

Remover, Drive Pinion Inner Bearing 205-489

Remover, Rear Wheel Hub Bearing Cup 205-283 (T88T-4628-A)

Installer, Drive Pinion Bearing Cup 205-486

Puller, Bearing 205-D064 (D84L-1123-A)

Gauge, Clutch Housing 308-021 (T75L-4201-A)

Installer, Drive Pinion Flange 205-285 (T88T-4851-A)

Depth Gauge, Drive Pinion 205-S156 (T80T-4020-A)


Dial Indicator Gauge with Holding Fixture 100-D002 (D78P-4201-B) or equivalent

Spreader, Differential Carrier 205-001 (TOOL-4000-E) or equivalent

Adapter for 205-S156 205-159 (T80T-4020-F42)

Depth Gauge/Aligner, Drive Pinion 205-280 (T88T-4020-A)

Gauge Tube 205-D038 (D81T-4020-F51) or equivalent

Handle 205-D055 (D81L-4000-A) or equivalent

Depth Gauge/Aligner, Drive Pinion (Handle) 205-281 (T88T-4020-B)

Slide Hammer 100-001 (T50T-100-A)

Installer, Drive Pinion Bearing Cup 205-024 (T67P-4616-A)

Installer, Drive Pinion Bearing 205-488

Protector, Drive Pinion Thread 205-487

Remover, Bushing 307-001 (TOOL-1175-AC) or equivalent

Draw Bar, Rear Axle 205-098 (T75T-1176-A)

Adapter for 205-S156 205-160 (T80T-4020-F43)

Seal Replacer Tool number not available at time of print

Material

Item Specification


WSP-M2C201-A

Additive Friction Modifier C8AZ-19B546-A or equivalent

EST-M2C118-A

Silicone Rubber F7AZ-19554-CA or equivalent

ESB-M4G92-A

Removal

1. Raise the vehicle on a hoist or raise the rear end of the vehicle with a jack. Install safety stands under the frame rails and lower the jack or hoist enough to allow the rear axle to drop into the rebound position for working clearance. For additional information, refer to Section 100-02.

2. Remove the differential housing cover and drain the lubricant from the rear axle. • Clean the gasket material from the differential housing cover and the differential

housing.

3. NOTE: An inspection can find the cause of the concern and determine the resolution.

Carry out the following before disassembly.

• Remove all the lubricant from the internal parts of the conventional differential assembly or Trac-Lok® differential assembly. Visually inspect the parts for wear and damage.

• Rotate the differential assembly to check for any roughness, indicating damaged bearings or gears.

• Remove all the lubricant and check the differential ring gear and pinion teeth for signs of scoring, abnormal wear, nicks and chips.

• Use a magnet to search for heavy metal particles indicating component damage.

4. CAUTION: The differential ring gear and pinion must be clean and dry to obtain an accurate reading.

NOTE: Measure the differential ring gear and pinion backlash at three equally spaced points.

Using the special tools, measure the differential ring gear and pinion backlash.

• The backlash tolerance is 0.13-0.20 mm (0.005-0.008 in) and cannot vary more than 0.05 mm (0.002 in) between points checked. A backlash variation of more than 0.05 mm (0.002 in) indicates gear/case runout.

• Move the differential ring gear toward the pinion to correct high backlash. • Move the differential ring gear away from the pinion to correct low backlash.

5. Remove the axle shafts. For additional information, refer to Section 205-02C.

6. CAUTION: Index-mark the driveshaft components to maintain driveline balance during assembly.

Disconnect the driveshaft at the rear axle, and position it aside. For additional information, refer to Section 205-01.

7. CAUTION: Note the positions of the mating letters stamped vertically and horizontally on the bearing caps and the differential housing before removing the bearing caps. Matching the letters is important at the time of assembly.

To ease removal of the differential assembly, loosen the bolts, then pry the differential case, bearing cups and outboard spacers outward until they are loose in the differential housing.

8. Remove the bolts and the bearing caps.

9. CAUTION: Do not spread the differential housing more than specified.

Using the special tools, spread the differential housing to the specification, then remove the Dial Indicator Gauge with Holding Fixture.

10. CAUTION: It will be necessary to use large pry bars to remove the differential assembly from the differential housing. Do not damage the differential ring rear when carrying out this step.

CAUTION: Mark or tag the differential bearing cups , indicating from which side they were removed.

Remove the differential assembly with the bearing cups.

• Remove the special tool after removing the differential assembly. • Inspect the differential bearing cups for deep scores, galling and spalling. Discard

them if necessary.

11. CAUTION: Mark or tag the outboard spacer(s) indicating from which side they were removed.

Remove the outboard spacer(s).

• Inspect the spacer(s) for nicks, bending and grooved conditions. Discard them if necessary.

12. CAUTION: Index-mark the pinion flange (4851) to the pinion shaft prior to removal.

Use a suitable tool to prevent the flange from turning, and remove the lock nut and washer.

13. Using the special tool, remove the pinion flange.

14. NOTE: There are drive pinion bearing preload shims on the spline-end of the pinion. These shims can stick to the pinion, the pinion bearing or they can fall out of the differential housing. Collect and keep the shims for reassembly.

Using a soft faced hammer and the special tool, tap the pinion out of the pinion bearing cup and remove it through the rear of the differential housing.

15. Using the special tools, remove and discard the pinion seal.

16. Remove the oil slinger and the pinion bearing.

17. CAUTION: Do not nick the differential housing bore.

Using the special tools, remove the outer pinion bearing cup.

18. Using the special tools, remove the inner pinion bearing cup.

19. The oil slinger, if so equipped, is part of the total drive pinion position shim height required to correctly set pinion depth. Keep the oil slinger intact for assembly.

20. Using the special tools, remove the inner pinion bearing.

21. NOTE: Discard the drive pinion position shim if bent or nicked. If discarding the shim, measure and record the shim thickness.

Remove the oil slinger, if so equipped, and the drive pinion position shim.

22. Carry out the following after disassembling the axle: • Thoroughly clean all parts. • Inspect all parts for damage and wear.

• CAUTION: Do not disassemble the Trac-Lok® differential assembly or the Truetrac® differential assembly. Discard the entire assembly if worn/damaged.

Clean the inside of the differential case before assembly. For Truetrac® differentials, submerge the entire differential assembly in a suitable solvent to wash away contaminates from within the housing.

� Thoroughly clean the differential housing if gears have scores/chips in them.

Installation

1. Carry out the Differential Case End Play Check in the General Procedures portion of this section.

2. Position the special tools and the inner and outer pinion bearing cups in their respective differential housing bores.

1. After placing the inner and outer pinion bearing cups in their bores, place the special tool (inner) on the inner pinion bearing cup.

2. Place the special tool (outer) on the outer pinion bearing cup.

3. Install the special tool.

3. Tighten the special tool to seat the pinion bearing cups into their bores.

4. CAUTION: Always install new pinion bearings when installing new bearing cups.

NOTE: If the feeler gauge can fit between a cup and the bottom of its bore at any point around the cup, remove and reseat the cup.

Check that the cups have seated correctly in their bores.

5. CAUTION: If any of the gauge surfaces have nicks in them, remove the high spots with a medium India oilstone to prevent erroneous readings.

NOTE: Apply only a light oil film on the pinion bearings before assembling the tools.

Assemble and position the following in the differential housing.

1. Position the screw (adapter for 205-S156).

2. Position the Alignment Adapter.

3. Position the inner pinion bearing.

4. Position the Drive Pinion Depth Gauge/Aligner.

5. Position the Gauge Block (adapter for 205-S156).

6. Position the outer pinion bearing.

7. Thread on the Drive Pinion Depth Gauge/Aligner (Handle).

6. NOTE: This step simulates pinion bearing preload.

Using a Nm (inch-pound) torque wrench, tighten the Handle to the specification.


1 205-160 Screw (Adapter for 205-S156)

2 205-D028 Alignment Adapter

3 4630 Rear (inner) pinion bearing

4 205-280 Drive Pinion Depth Gauge/Aligner

5 205-159 Gauge Block (Adapter for 205-S156)

6 4621 Front (outer) pinion bearing

7 205-281 Drive Pinion Depth Gauge/Aligner (Handle)

7. NOTE: Offset the Gauge Block to obtain an accurate reading.

Rotate the Gauge Block several half-turns to make sure the pinion bearings are correctly seated and position the Gauge Block.

8. Install the special tool. 1. Position the special tool.

2. Install the bearing caps.

3. Install the four bolts.

9. NOTE: Use a feeler gauge or flat, clean drive pinion position shims as a measuring device.

NOTE: Do not attempt to force the gauge or shim between the Gauge Block and the Gauge Tube. A slight drag indicates a correct selection.

Using a feeler gauge or flat, clean drive pinion position shims, measure between the Gauge Block and the Gauge Tube. Record the measurement. Refer to Pinion Ring Gear Variation Number in this section for shim selection information.

• Remove the special tools after making the correct shim selection.

10. CAUTION: Follow the drive pinion bearing preload shim and drive pinion position shim assembly sequence as directed or unit failure can result.

Install the correct thickness drive pinion position shim, and the oil slinger, if so equipped, on the pinion.

11. NOTE: Always use the same new inner pinion bearing installed when taking the measurement for drive pinion position shim selection.

Using the special tool, an axle bearing/seal plate, and a suitable press, install the pinion bearing.

12. NOTE: Use the thickness of the old drive pinion bearing preload shims as a starting point for setting pinion bearing preload.

Inspect the drive pinion bearing preload shims for damage. Discard them if necessary. New shims are available in the thickness shown in the following chart.

Available Drive Pinion Bearing Preload Shims

mm Inches

0.36 0.014

0.38 0.015

0.41 0.016

0.46 0.018

0.51 0.020

0.53 0.021

0.56 0.022

0.58 0.023

0.76 0.030

13. Assemble the drive pinion bearing preload shims onto the pinion and install the pinion into the differential housing.

14. Install the outer pinion bearing.

15. Using the special tool, install the pinion flange.

16. Install the old washer and the lock nut.

17. Using a Nm (inch-pound) torque wrench, rotate the pinion. The torque must read as specified.

• To increase the preload, remove drive pinion bearing preload shims. To decrease the preload, add shims.

18. If the pinion bearing preload is within specification, and the pinion position shim has changed, change the drive pinion bearing preload shims by the same amount.

• The direction arrow pointing toward the pinion flange indicates that by removing the drive pinion position shim, the distance from the centerline of the tubes to the pinion backface increases, giving a plus (+) reading. The drive pinion bearing preload shim pack does not affect the pinion depth setting. However, if the pinion position is changed, the pinion preload will change and may require adjustment to bring the torque-to-rotate within specification. Arrows on the ring gear illustrate the method to increase or decrease backlash and differential bearing preload.

19. With the drive pinion at the correct preload as determined earlier in this procedure, remove and discard the lock nut and the washer.

20. Using the special tool, remove the pinion flange.

21. Coat the pinion seal rubber lips with lubricant.

22. Using the special tool, install the pinion seal. • After installation, verify that the garter spring did not pop out of the seal. If the

garter spring popped out, install a new pinion seal.

23. Coat the inside of the pinion flange with a small amount of lubricant.


25. CAUTION: Always install a new washer and lock nut.

Install the new washer and lock nut.

26. Carry out the Ring Gear and Pinion Backlash procedure in the General Procedures portion of this section.

27. Assemble the differential bearing cups to the differential bearings.

28. CAUTION: Do not spread the differential housing more than specified.

CAUTION: Avoid nicking the ring gear teeth and the anti-lock speed sensor ring during assembly.

Using the special tools, spread the differential housing to the specification.

• Use a rawhide hammer to seat the differential into the differential housing pocket. � Remove the special tools.

29. CAUTION: Match the mating letters as noted during disassembly.

Install the bearing caps, aligning the letters with those on the differential housing. Tighten the bolts to specification.

30. Using the special tools, measure the differential ring gear and pinion backlash at three equally spaced points.

• The backlash tolerance is 0.13-0.203 mm (0.005-0.008 in) and cannot vary more than 0.05 mm (0.002 in) between points checked. A backlash variation of more than 0.05 mm (0.002 in) indicates gear/case runout.

• Move the differential ring gear toward the pinion to correct high backlash. • Move the differential ring gear away from the pinion to correct low backlash. • Moving a specified amount of differential bearing shims from one side of the

differential to the other makes these corrections.

31. Confirm the total preload. • Using a Nm (inch-pound) torque wrench, check the torque to rotate the pinion.

The reading must be higher than the initial reading (taken without the differential case installed) by the amount shown, with new bearings installed as recommended.

• If the total preload is too high, remove an equal amount of differential bearing shims from each differential case hub. If the total preload is too low, add an equal amount of differential bearing shims to each differential case hub.

32. Carry out the Tooth Contact Pattern Check to verify the final pinion position is correct. For additional information, refer to Section 205-00.

33. Install the axle shafts. For additional information, refer to Section 205-02C.

34. CAUTION: Clean both flat surfaces (differential housing and differential housing cover) with a suitable solvent to remove all traces of oil film.

CAUTION: Install the differential housing cover within 15 minutes of applying the silicone, or it will be necessary to remove and reapply new sealant.

NOTE: The differential housing cover requires a silicone rubber sealer material, rather than a gasket.

Apply a continuous bead of sealant of the specified thickness to the differential housing cover.

35. Place two bolts into the differential housing cover at the 8 o'clock and 2 o'clock positions. Install the differential housing cover.

• Use the two bolts to position the differential housing cover on the differential housing.

36. Install the remaining bolts. Tighten the bolts alternately and evenly. • Allow 1-hour cure time before filling the axle with the correct amount of

specified lubricant.

37. NOTE: Align the index marks made during removal.

Connect the driveshaft to the rear axle. For additional information, refer to Section 205-01.

38. CAUTION: For Trac-Lok® axles, first fill the axle with 0.2365 liters (0.5 pints) of Additive Friction Modifier.

Fill the axle with the specified type and amount of lubricant. For additional information, refer to Specifications in this section.




Driveshaft





Drive Pinion Flange

1. For additional information, refer to Drive Pinion Seal in this section.




Drive Pinion Seal

Special Tool(s)

2 Jaw Puller 205-D026 (D80L-1002-L) or equivalent

Installer, Drive Pinion Flange 205-285 (T88T-4851-A)


Pinion Oil Seal Replacer Tool number not available at time of print


Material

Item Specification


WSP-M2C201-A

Removal

1. Raise the vehicle on a hoist or raise the rear end of the vehicle with a jack. Install safety stands under the frame rails and lower the jack or hoist far enough to allow the rear axle to drop into the rebound position for working clearance.

2. NOTE: To maintain driveline balance, mark the driveshaft components so they can be reinstalled in their original positions.

Disconnect the driveshaft at the rear axle, and position it aside. For additional information, refer to Section 205-01.

3. NOTE: Index-mark the flange (end yoke for Motorhome) to the pinion shaft.

While using a suitable tool to prevent the flange or yoke from turning, remove the pinion nut.

4. Using the 2 Jaw Puller, remove the flange or yoke.

5. Using the Bushing Remover and the Slide Hammer, remove the pinion seal.

6. Clean the rear axle pinion seal seat.

Installation

1. CAUTION: Installation without the correct tool can result in early seal failure. If the pinion seal becomes cocked during installation, remove and install a new one. Make sure the garter spring remains in place during assembly. If the spring is dislodged, a new pinion seal must be installed.

NOTE: Drive the pinion seal into the housing, using the Pinion Oil Seal Replacer.

NOTE: The pinion flange or end yoke must never be hammered on or installed with power tools.

NOTE: Install the flange or yoke using the Drive Pinion Flange Installer.


• Coat the pinion seal (rubber lips) with lubricant.



Workshop Manual


Axle Assembly

Special Tool(s)

Wheel Dolly 014–00030 or Equivalent

Removal

1. Set the parking brake.

2. Chock the front wheels.

3. Loosen, but do not remove, the rear wheel lug nuts.

4. Raise and support the rear of the vehicle high enough so that it will clear the axle assembly when removing it.

5. Remove the rear wheels using the Wheel Dolly.

6. Release the parking brake cable tension, and disconnect the cables at the equalizer and the anchor plate; for additional information, refer to Section 206-05.

7. Remove the frame anchors, and position the parking brake cables aside.

8. Disconnect the rear anti-lock brake sensor electrical connector. Release the harness clips and position the harness aside.

9. NOTE: To maintain driveline balance, mark the driveshaft components so they can be reinstalled in their original positions.

Disconnect the driveshaft, and position it aside; for additional information, refer to Section 205-01.

10. Disconnect the sway bar at the sway links.

11. Disconnect the shock absorbers at the axle.

12. Disconnect the hydraulic brake hose and axle vent hose at the crossmember. Plug the brake hose and brake line, and position the hoses aside.

13. CAUTION: The nose of the axle will drop downward when loosening the U-bolts. Make sure to support the axle nose as well as the rear of the housing with the jack.

Support the axle with a suitable floor jack.

14. Remove the U-bolt nuts, the spring seat caps and the U-bolts.

15. WARNING: Watch for obstructions while lowering and removing the axle.

Carefully lower the axle and remove it.

Installation


• Refer to Section 204-02 for the shock absorber, the sway bar and the U-bolt torque specifications.

• Refer to Section 204-04 for the wheel lug nut torque specifications.

2. Bleed the brakes; for additional information, refer to Section 206-00.

3. Make sure the axle lubricant level is proper; refer to Specifications in this section.



Workshop Manual



Special Tool(s)

Puller, Drive Pinion/Differential Carrier 205-D036 (D81L-4220-A) or equivalent

Material

Item Specification

Premium Long Life Grease XG-1-C or equivalent

ESA-M1C75-B

Threadlock and Sealer E0AZ-19554-AA

WSK-M2G351-A5

Disassembly

All differentials

1. NOTE: Differential bearing shims are available in thicknesses of 0.762, 0.787, 0.813, 0.838, 0.864, 0.889 and 0.914 mm (0.030, 0.031, 0.032, 0.033, 0.034, 0.035 and 0.036 in).

NOTE: If damaged, install new differential bearing shims.

NOTE: Install new differential bearings if removing them from the differential case.

Using the special tool, remove the differential bearings.

• Wire the differential bearing shims, differential bearing cup, differential bearing, and selective outboard spacer(s) together. Note from which side they were removed (differential ring gear side or the opposite side).

2. NOTE: Use a vise with brass jaws or wood blocks.

Place the differential case in a vise.

3. CAUTION: Do not damage the anti-lock speed sensor ring when removing the differential ring gear. If removing the anti-lock speed sensor ring, discard it and install a new one.

NOTE: Always install new bolts upon assembly. Use Grade 9 bolts for all Dana rear axles.

Remove the bolts. Leave four bolts loosely assembled, 90 degrees apart.

4. Tap each bolt head alternately with a rawhide or plastic hammer to loosen the differential ring gear. Remove the bolts and the differential ring gear.

5. If necessary, remove the anti-lock speed sensor ring with a soft-faced hammer. Discard the anti-lock speed sensor ring.

6. The Truetrac® and Trac-Lok® differential assemblies are non-repairable. Discard the entire assembly if it is worn/damaged. For conventional differential assemblies, proceed as follows.

Conventional differential

7. NOTE: Use a vise with brass jaws or wood blocks.


8. Using a small drift, drive out the differential pinion shaft lock pin.

9. Using a drift, remove the differential pinion shaft.

10. To remove the differential side gears and the differential pinion gears, rotate the differential side gears. The differential pinion gears will turn to the opening in the differential case.

11. Remove the differential pinion gears and the differential pinion thrust washers behind the differential pinion gears.

12. Lift out the differential side gears and the differential side gear thrust washers.

Assembly

Conventional differential

1. NOTE: For Truetrac® and Trac-Lok® differential assemblies proceed to All differentials in this procedure.

NOTE: Use a vise with brass jaws or wood blocks.


2. Lubricate the new differential side gear thrust washers, the thrust face of the new differential side gears, the new differential pinion thrust washers, and the new differential pinion gears with grease.

3. NOTE: The best way to assemble the differential side gears and the differential pinion gears is to lubricate all parts with the specified rear axle lubricant.

Lubricate and assemble both differential side gears and differential side gear thrust washers. Hold them in place. Then, lubricate and assemble the differential pinion gears and the differential pinion gear thrust washers to hold the differential side gears in place.

4. NOTE: Rotate the differential side gears until the holes of the differential pinion gear thrust washers and the differential pinion gears line up with the holes of the differential case. If the differential pinion gears will not rotate by hand, install one of the axle shafts into the spline of the differential side gear and use a pipe wrench to turn the axle shaft.

Using a drift, line up the holes with those of the differential case.

5. Assemble the differential pinion shaft and drive on the differential pinion shaft to remove the drift. Align the lock pin hole in the differential pinion shaft with the lock pin hole in the differential case.

6. Assemble the differential pinion shaft lock pin. Peen the metal of the differential case over the differential pinion shaft lock pin in two places, 180 degrees apart, to lock it in place. Note the location of the slot in the differential pinion shaft lock pin and peen it 90 degrees apart.

All differentials

7. NOTE: Align the tab on the anti-lock speed sensor ring with the slot in the differential case.

NOTE: Apply Threadlock® and Sealer to the new bolts.

Align the tab in the anti-lock speed sensor ring with the slot in the differential case. Start the two bolts through the differential case flange and into the differential ring gear to make sure the differential case and the differential ring gear bolt hole align.

8. Press the anti-lock speed sensor ring on the differential case. The differential case flange acts as a pilot for the anti-lock speed sensor ring.

9. NOTE: Apply Threadlock® and Sealer to the new bolt threads.

Draw up the Grade 9 bolts alternately and evenly.

10. Install the differential bearings. For additional information, refer to Differential Case and Pinion Set Up in this section.

SECTION 205-02B:

Rear Drive Axle/Differential — Dana S135

SPECIFICATIONS





IN-VEHICLE REPAIR

Axle Shaft

Driveshaft

Drive Pinion Flange

Pinion Seal

Drive Pinion

Differential Carrier


Axle Assembly



Drive Pinion





Item Specification

Lubricants/Adhesive/Sealants

Ford Gasket Maker F8AZ-19B508-AB WSK-M2G348-A5


Threadlock 262 E2FZ-19554-B WSK-M2G351-A6

Motorcraft SAE 75W-140 Synthetic XY-75W140-QL WSL-M2C192-A

Capacity

Rear axle lubricant 11.6 liters (24.5 pints)1

Clearance, Tolerance and Adjustments

Differential ring gear rivet pressure 41-45 Metric Tons (45-50 Tons)

Pinion bearing preload2 1.1298-4.5192 Nm (10-40 lb-in)

Differential ring gear to pinion backlash3 0.15-0.30 mm (0.06-0.012 inch)

1 The lubricant capacity will vary depending upon the housing mounting angle. The capacity given is for an angle of 4 degrees. A lubricant level close enough to the bottom of the fill hole to be seen or touched is not sufficient. The lubricant must be level with the fill hole. 2 Establish the pinion bearing preload prior to pinion seal installation. 3 The acceptable backlash tolerance is ± 0.0508 mm (0.002 inch) from the backlash etched in the differential ring gear. The tooth contact pattern can move only by adjusting backlash. The tooth contact pattern can move only in the direction of heel-to-toe, and toe-to-heel. Depth of the tooth contact pattern is not adjustable. Contact Spicer Service at 1-800-666-8688 for assistance if you are unable to establish an acceptable tooth contact pattern within the limits of backlash.



Adjusting ring lock bolt 37 25

Carrier mounting bolt 136-163 101-121

Differential bearing cap bolt 169 125

Differential case bolt 149 110

Drain plug 47-61 35-45

Fill plug 47-61 35-45

Pinion hex nut 1085 800

SECTION 205-02B: Rear Drive Axle/Differential

— Dana S135 1999 F-Super Duty 250-550

Workshop Manual



Dana Model S135 Full-Floating Rear Drive Axle

Identification Tags

Item Description

1 Carrier identification tag

2 Dana part number (complete assembly number)

3 Customer part number (optional)

4 Julian date code

5 Line set number (optional)

6 Axle ratio

7 Last six digits of the vehicle serial number (optional)

8 Axle assembly identification tag

9 Model

Gear Set Identification

Item Description

1 Trademark

2 Match set number

3 Manufacturing date

4 Heat code

5 Part number

6 Tooth combination

• The trademark shows the company logo, and identifies the location of the manufacturing facility.

• CAUTION: Never mate a differential ring gear and pinion together that does not have the same matched set numbers. Always install a new matched set if discarding either the differential ring gear or the pinion.

A corresponding number marked on the differential ring gear and pinion identifies them as a matched set.

• The manufacturer's date identifies the gear set's date of fabrication. • The tooth combination identifies the number of teeth on the pinion and the number of

teeth on the differential ring gear. A tooth combination of 41-11, for example, would indicate that the pinion has 11 teeth and the ring gear has 41 teeth that results in a 3.73:1 ratio.

Dana Model S135 Full-Floating Rear Axle, Disassembled View

Item Part

Number Description

1 4234 Axle shaft

2 4N292 Fill plug

3 4022 Breather

4 4010 Differential housing

5 4N282 Drain plug

6 4067 Differential bearing adjusting ring

7 4222 Differential side bearing cup

8 4221 Differential side bearing cone

9 4216 Differential case bolt

10 4204 Differential case half (conventional differential)

11 4228 Thrust washer (conventional differential)

12 4237 Differential side gear (conventional differential)

13 4230 Thrust washer (conventional differential)

14 — Differential pinion mate (conventional differential) (part of 4237)

15 4211 Differential cross shaft (conventional differential)

16 4558 Differential ring gear rivet

17 4209 Differential ring gear (matched set)


19 — Differential bearing cup bolt (part of 4141)

20 — Washer (part of 4141)

21 — Differential bearing cap (part of 4141)

22 — Adjusting ring lock bolt (part of 4141)

23 4143 Adjusting ring lock

24 4209 Pinion (matched set)

25 4621 Pinion bearing cone, inner

26 — Pinion bearing cup, inner

27 4141 Carrier housing

28 4616 Carrier mounting bolt

29 4537 Pinion preload spacer (selective)

30 4628 Pinion bearing cup, outer

31 4630 Pinion bearing cone, inner

32 4676 Pinion seal


34 4320 Pinion hex nut

35 4026 Differential assembly (Truetrac®)

NOTE: Unless noted, the procedures in this section apply to both the conventional differential and the Truetrac® differential, though most of the illustrations used in the procedures show the conventional differential.

The Model S135 rear axle features the following:

• a hypoid design differential ring gear and pinion • a two-bearing overhung pinion mounting • full-floating axle shafts • an HLSA steel differential housing • a front mounted removable one-piece carrier housing • a conventional differential assembly or a Truetrac® limited slip differential assembly









Axle Shaft





Driveshaft





Drive Pinion Flange

1. Refer to Drive Pinion, Disassembly and Assembly in this section.




Pinion Seal





Drive Pinion





Differential Carrier

Removal

WARNING: Do not use heat when disassembling a drive axle. To do so will destroy heat treat properties and weaken or distort axle components. Failure to follow these instructions may result in personal injury.

1. CAUTION: Steam clean the axle prior to removal from the vehicle. Dirt is abrasive and will cause premature wear of otherwise usable parts.

Steam clean the axle assembly.


3. Chock the wheels.

4. Drain the axle lubricant into a suitable container. 1. Remove the drain plug.

2. Clean and install the drain plug when the lubricant has drained.

5. Disconnect the rear anti-lock brake sensor electrical connector.

6. Index-mark and disconnect the driveshaft, and position it aside. For additional information, refer to Section 205-01.

7. Loosen the pinion hex nut if drive pinion disassembly is necessary.

8. WARNING: Do not strike the axle shaft flange directly with a steel hammer or sledge. This will crack and splinter the flange. Failure to follow these instructions may result in personal injury.

CAUTION: Do not pry or chisel the axle shaft flange away from the hub. This will damage the sealing surface.

NOTE: Mark the left or right axle shaft flange for proper orientation during installation.

Remove the axle shafts. For additional information, refer to Section 205-02C.

9. Remove all but the two top carrier-to-axle housing retaining bolts, noting the length and position of each bolt.

10. WARNING: Secure the carrier to the jack to prevent it from falling when removing it from the axle housing. Failure to follow these instructions may result in personal injury.

Remove the carrier from the axle housing.

1. Position a suitable jack under the carrier.

2. Remove the remaining retaining bolts.

3. Use the slots to separate the carrier approximately 25.4-50.8 mm (1-2 inches) from the axle housing.

4. Secure the carrier to a suitable jack, and remove the carrier from the axle housing.

11. CAUTION: Alkaline cleaning solutions will damage machine surfaces. Use only emulsion cleaners or petroleum based cleaning solvent.

CAUTION: Use only soft, clean, lintless towels to dry the components.

CAUTION: After drying, lightly coat the parts with rust inhibitor or clean lubricant to prevent damage from corrosion. Wrap all parts that are going to be in storage for a prolonged period in wax paper.

Clean and dry the components as necessary.

12. NOTE: The gear set shown removed for clarity.

Inspect the gear set for pitting, scoring, wear and damage.

13. Inspect the splines for wear, cracking and distortion from twisting.

14. Inspect the axle flange O-ring.

15. Clean the axle housing interior, the axle and carrier housing sealing surfaces, and the carrier mounting bolt hole threads. Inspect the housing for stripped and damaged threads and bending fatigue.

16. If carrier disassembly is necessary, refer to Differential Case and Ring Gear in this section.

Installation

1. CAUTION: The gasket material must cure for one hour before filling the axle with lubricant.

Apply a continuous bead of Ford Gasket Maker F8AZ-19B508-AB or equivalent meeting Ford specification WSK-M2G348-A5 onto the axle housing mounting flange and around each bolt hole.

2. Thread two studs into the axle housing 180 degrees apart. This will eliminate rotation of the carrier assembly after it makes contact with the gasket material.

3. WARNING: Secure the carrier to the jack to prevent it from falling. Failure to follow these instructions may result in personal injury.

Position the carrier into the axle housing.

4. CAUTION: Make sure the bolt threads are clean.

Apply Threadlock 262 E2FZ-19554-B or equivalent meeting Ford specification WSK-M2G351-A6 to the bolt threads, and install the bolts.

• Remove the two alignment studs only after installing several of the bolts. • Tighten the bolts in a cross pattern.

5. Install the axle shafts. For additional information, refer to Section 205-02C.

6. Connect the driveshaft. For additional information, refer to Section 205-01.

7. Connect the rear anti-lock brake sensor electrical connector.

8. Remove the fill plug.

9. CAUTION: A lubricant level close enough to the bottom of the fill hole to be seen or touched is not sufficient. The lubricant must be level with the fill hole.

Fill the axle with Motorcraft SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A until the lubricant is level with the fill hole.

10. Clean and install the fill plug.

11. Remove the wheel chocks.

12. Release the parking brake.




Axle Assembly

Special Tool(s)

Wheel Dolly 014-00030 or Equivalent

Removal


2. Chock the front wheels.

3. Loosen, but do not remove, the rear wheel lug nuts.

4. Raise and support the rear of the vehicle high enough so that it will clear the axle assembly when removing it.

5. Remove the rear wheels using the Wheel Dolly.

6. Release the parking brake cable tension, and disconnect the cables at the equalizer and the anchor plate; refer to Section 206-05.

7. Remove the frame anchors, and position the parking brake cables aside.

8. Disconnect the rear anti-lock brake sensor electrical connector. Release the harness clips and position the harness aside.

9. Index and disconnect the driveshaft, and position it aside; refer to Section 205-01.

10. Disconnect the sway bar at the sway links.

11. Disconnect the shock absorbers at the axle.

12. Disconnect the hydraulic brake hose and axle vent hose at the crossmember. Plug the brake hose and brake line, and position the hoses aside.

13. Support the axle with a suitable floor jack.

14. NOTE: Mark the front of each spring seat cap for proper orientation during installation.

Remove the U-bolt nuts, the spring seat caps and the U-bolts.

15. WARNING: Watch for obstructions while lowering and removing the axle.

Carefully lower the axle and remove it.

Installation

1. Follow the removal procedure in reverse order. • Refer to Section 204-02 for the shock absorber, the sway bar and the U-bolt

torque specifications. • Refer to Section 204-04 for the wheel lug nut torque specifications.

2. Bleed the brakes; refer to Section 206-00.

3. Make sure the axle lubricant level is proper; refer to Specifications in this section.





Special Tool(s)

Puller, Bearing 205-D064 (D84L-1123-A) or equivalent

Lifting Sling (1" x 5') 100-D008 (D87L-1000-A) or equivalent

Material

Item Specification

Threadlock 262 E2FZ-19554-B

WSK-M2G351-A6

Disassembly

1. Mount the carrier housing in a suitable repair stand.

2. CAUTION: If reusing the differential ring gear and pinion, measure and record the backlash before disassembly. Assembling the differential ring gear and

pinion to the recorded backlash will match the established wear patterns. Hand rolled patterns will cover less area than the established patterns.

Measure and record the differential ring gear and pinion backlash.

• Check the backlash in four equally spaced positions around the differential ring gear.

• The tooth contact pattern can move only by adjusting backlash. The tooth contact pattern can move only in the direction of heel-to-toe, and toe-to-heel. Depth of the tooth contact pattern is not adjustable. Contact Spicer Service at 1-800-666-8688 for assistance if you are unable to establish an acceptable tooth contact pattern within the limits of backlash.

3. Remove the rear anti-lock brake sensor.

4. Remove the adjusting ring locks.

5. Loosen, but do not remove, the four bolts.

6. Relieve the bearing preload. • Loosen each differential bearing adjusting ring.

7. NOTE: The differential bearing caps are match marked at the factory.

Remove the bolts, bearing caps and adjusting rings.

8. CAUTION: Do not damage the differential ring gear and pinion.

Using the special tool, carefully lift the differential subassembly out of the carrier.

9. Using the special tool, and a suitable puller, remove the differential side bearings if worn or damaged.

10. The Truetrac® differential assembly is non-repairable. Discard the entire assembly if it is worn or damaged.

11. On the conventional differential assembly, separate the differential case halves. 1. Match mark the case halves.

2. Remove the bolts.

3. Separate the case halves.

12. On the conventional differential assembly, remove the gear assembly. 1. Remove the thrust washer and differential side gear.

2. Remove the differential cross shaft with the pinion mates and the thrust washers.

3. Remove the differential side gear and thrust washer.

13. CAUTION: Do not use a chisel to remove the rivet heads. This will damage the differential case.

CAUTION: Use a soft hammer to strike the punch.

If discarding the pinion or differential ring gear, carefully center punch each differential ring gear rivet.

14. Drill the rivet heads to the depth shown using the specified size drill bit.

15. Separate the differential ring gear from the case.

1. CAUTION: Use a soft hammer to strike the punch.

Drive out the remaining rivet portions with a rounded type punch.

2. Separate the differential ring gear from the case.

3. CAUTION: Discard the anti-lock speed sensor ring if separating it from the case half.

If necessary, remove the anti-lock speed sensor ring and discard it.


CAUTION: Use soft, clean, lintless towels to dry the components.

CAUTION: Never spin-dry bearings with compressed air. This will damage the mating surfaces due to a lack of lubrication.


NOTE: For Truetrac® differentials, submerge the entire differential assembly in a suitable solvent to wash away contaminants from within the housing.

Clean and dry the components.

17. Inspect the bearing surfaces for pitting, wear and overheating.

18. Inspect the following: • the differential case machine surfaces. • the differential ring gear mounting holes for deformities, such as egg shaping. • all surfaces for nicks and cracks.

19. Inspect the thrust washers for scoring and cracking.

20. CAUTION: Discard all gears in sets if one or more sustains wear or damage.

Inspect the gears for pitting, scoring, wear and damage.

21. Inspect the shafts for nicks and scores.

22. Refer to Drive Pinion in this section if disassembly is necessary.

Assembly

1. Assemble the differential ring gear and, if removed, a new anti-lock speed sensor ring to the differential case.

1. Align the tab on the sensor ring with the notch in the case flange.

2. Bolt the differential ring gear to the case in three places, 120 degrees apart.

2. NOTE: Proceed to the next step of this procedure if not installing a new anti-lock speed sensor ring.

Press the anti-lock speed sensor ring on the case flange.

3. CAUTION: Compress the rivet before removing the bolts from the differential ring gear and case to prevent differential ring gear runout.

Install each rivet, using a suitable hydraulic or mechanical press and riveting fixture and applying the force specified.

4. CAUTION: Place the differential side bearing cups on the differential side bearings after pressing the bearings on the case. This will prevent bearing damage during the remaining assembly process.

Press the differential side bearings on the differential case halves, and place the bearing cups on the bearings.

5. NOTE: Lightly lubricate all of the mating surfaces with clean axle lubricant. This will aid in assembly and provide initial lubrication.

On the conventional differential, install the gear assembly.

1. Position the thrust washer and the differential side gear into the case half.

2. Position the differential cross shaft with the pinion mates and the thrust washers into the case half.

3. Position the differential side gear and thrust washer on the differential pinion mates.

6. CAUTION: Align the match marks.

On the conventional differential, assemble the differential case halves.

7. CAUTION: Do not damage the differential ring gear and pinion.

Using the special tool, carefully position the differential subassembly into the carrier.

8. CAUTION: The bearing cups must seat on the differential side bearings.

CAUTION: Align the match marks.

Install the differential bearing caps.

1. Position the bearing cap onto the leg.

2. CAUTION: The bolt threads must be clean.

Apply Threadlock 262 to the bolt threads, and install the bolts.

� Tighten the bolts enough to eliminate visible space between the bearing cap and leg. Do not tighten the bolts to the appropriate torque at this time.

9. CAUTION: Align the differential assembly within th e bearing bores before applying preload or damage to the bearings will result.

Install the differential bearing adjusting rings.

• Tighten both adjusting rings until there is zero end play, and some backlash between the differential ring gear and pinion. Make sure the adjusting ring tooth aligns so that installation of the adjusting ring lock is possible.

10. Set the backlash at zero. • NOTE: The adjusting ring tooth must always align so that installation of the

adjusting ring lock is possible.

Loosen the adjusting ring on the tooth side of the differential ring gear one tooth, and tighten the opposite adjusting ring one tooth. Repeat this process until backlash is at zero.

11. Set the backlash and the bearing preload to specifications. • With a new matched set installed, set the backlash to the specification etched in

the differential ring gear. • With the original matched set installed, set the backlash to the specification

recorded prior to disassembly. • NOTE: The adjusting ring tooth must always align so that installation of the

adjusting ring lock is possible.

Tighten the adjusting ring on the tooth side of the differential ring gear until backlash is within specifications.

12. Check the differential ring gear and pinion backlash in four equally spaced positions around the differential ring gear.

• The acceptable backlash tolerance is ± 0.0508 mm (0.002 inch) from the backlash etched in the differential ring gear.

• If the backlash tolerance varies more than 0.080 mm (0.003 inch) between the four positions, remove the differential and determine the cause.

13. Tighten the bolts. • Check the differential ring gear and pinion backlash, as described in the previous

step, after tightening the bolts.

14. Install the adjusting ring locks.

15. Install the rear anti-lock brake sensor.

16. Install the carrier. For additional information, refer toDifferential Carrier in this section.




Drive Pinion

Special Tool(s)

Installer, Drive Pinion Oil Seal 205-S438

Installer, Yoke 205-S434

Remover, Yoke 205-433

Material

Item Specification

Stud and Bearing Mount E0AZ-19554-BA

WSK-M2G349-A1

Disassembly

1. Remove the hex nut.

2. CAUTION: Hammering on the pinion flange will close in the bearing bores and misalign the flange lugs. This will result in premature failure of the journal needle bearings. Serious damage will also occur internally to the differential ring gear and pinion set or pinion bearings by hammering on external parts. Remove and install the pinion flange using only the procedures in this section.

Using the special tool, remove the pinion flange.

3. Remove the pinion seal.

4. CAUTION: Position a block of wood under the pinion to avoid damage to the gear teeth.

NOTE: The outer bearing is press fit.

Press the pinion through the outer pinion bearing, and remove the pinion.

5. Remove the pinion preload spacer. • Measure and record the spacer thickness. Set the spacer aside for use in assembly.

6. If reusing the gear set, remove the inner pinion bearing with a suitable puller.

7. If new pinion bearings are being installed, remove the outer and inner pinion bearing cups.


CAUTION: Use soft, clean, lintless towels to dry the components.

CAUTION: Never spin-dry bearings with compressed air. This will damage the mating surfaces due to a lack of lubrication.


Clean and dry the components as necessary.

9. Inspect the pinion flange for grooves in the sealing surface caused by contamination. • If grooves are detectable with a fingernail, repair the flange with a CR approved

sleeve or install a new flange.

Assembly

Initial Assembly

1. Press the inner pinion bearing onto the pinion.

2. Press the inner and outer pinion bearing cups into the carrier until seated. • Use a 0.0381-mm (0.0015-inch) feeler gauge to verify the bearing cups have

completely seated in the bearing bores. • Lubricate the bearing cups and cone.

3. Seat the outer pinion bearing on the pinion. 1. Seat the inner pinion bearing into the cup by positioning a 152.4 x 152.4 x 152.4-

mm (6 x 6 x 6-inch) block of wood under the pinion.

2. Place the original pinion preload spacer onto the pinion.

3. Place the outer pinion bearing onto the pinion.

4. Using a suitable press, seat the outer bearing on the pinion.

4. NOTE: Do not install the pinion seal at this time.

Using the special tool, install the pinion flange.

5. Install the hex nut. • Using a suitable torque multiplier, tighten the hex nut.

Measuring pinion bearing preload torque

6. Measure the torque to rotate. • Take torque measurements every fourth revolution. • Proceed to Pinion bearing preload adjustment in this procedure if the bearing

preload torque is not within the specifications. Proceed to Final assembly in this procedure if the bearing preload torque is within the specifications.

Pinion bearing preload adjustment

7. NOTE: Also refer to the following illustration.

Adjust the pinion bearing preload by installing a new pinion bearing preload spacer.

• To increase the preload, install a thinner spacer. To decrease the preload, install a thicker spacer.

• The pinion bearing preload spacers are available in sizes from 7.26 to 8.00 mm (0.286 to 0.315 inch).

• Always measure the new spacer before installing it. • On a flat surface, sand the next thicker size spacer with emery cloth to the

required thickness to obtain a closer adjustment. Thoroughly wash the spacer to remove the emery cuttings before installation.

• A 0.0254 mm (0.001 inch) change in the spacer thickness will change the torque rate approximately 3.3894 Nm (30 lb-in).

• Repeat Measuring pinion bearing preload torque and Pinion bearing preload adjustment in this procedure until the rotational torque is within specifications.

Final assembly

8. Using a suitable torque multiplier, remove the hex nut.

9. CAUTION: Hammering on the pinion flange will close in the bearing bores and misalign the flange lugs. This will result in premature failure of the journal

needle bearings. Serious damage will also occur internally to the differential ring gear and pinion or pinion bearings by hammering on external parts. Remove and install the pinion flange using only the procedures in this section.

Using the special tool, remove the pinion flange.

10. Using the special tool, install the pinion seal. • A rotational torque of 1.6947-5.0841 Nm (15-45 lb-in) is acceptable with the

pinion seal installed.


12. Apply Stud and Bearing Mount to the pinion threads, and install a new hex nut. Using a suitable torque multiplier, tighten the nut.

13. Assemble the carrier. For additional information, refer to Differential Case and Ring Gear in this section.

SECTION 205-02C:

Wheel Hubs and Bearings — Full Floating Axle — Dana

SPECIFICATIONS


Wheel Hubs and Bearings




Axle Shaft

Hub

Bearings, Cups and Seals

SECTION 205-02C: Wheel Hubs and Bearings —

Full Floating Axle — Dana 1999 F-Super Duty 250-550

Workshop Manual

SPECIFICATIONS Procedure revision date:

01/26/2000


Item Specification

Lubricant



Description Nm Lb-Ft

Rear hub nut (To set bearings, back off the hub nut 90 degrees, retighten.)

95 24a

70 18

Axle shaft bolts 133 98

Rear hub bolts 89-119 66-88 a Maximum torque to rotate the hub is 2.3 Nm (20 lb-in) when the end play is zero.



DESCRIPTION AND OPERATION Procedure revision date:

01/26/2000


F-350


1 4234 Axle shaft

2 — O-ring (part of 4234)

3 1124 Hub nut

4 1240 Outer rear wheel bearing

5 1239 Rear wheel bearing outer cup

6 1109 Rear hub and rotor assembly

7 1243 Rear wheel bearing inner cup

8 1244 Inner rear wheel bearing

9 1175 Rear hub seal

F-450 and F-550


1 4A140 Axle shaft bolt

2 1001 Rear axle shaft gasket

3 1012 Wheel nut

4 2C026 Brake disc

5 1244 Inner rear wheel bearing

6 1175 Hub seal

7 1109 Rear hub (includes bearing cups)

8 1240 Outer rear wheel bearing

9 1A124 Hub nut

10 4234 Axle shaft

The rear hub (1109) is supported or floats on the axle spindle on two opposing tapered roller bearings. A rear hub seal is installed behind the inner rear wheel bearing to prevent rear axle lubricant from leaking onto the rotor. The rear hub is retained on the spindle by a ratcheting hub nut tabbed to a slot on the spindle.

The rear wheel bearings are packed with a lithium base grease, Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B, to provide initial lubrication until axle lubricant flows into the rear hubs and the inner rear wheel bearings during vehicle operation.



DIAGNOSIS AND TESTING Procedure revision date:

01/26/2000





REMOVAL AND INSTALLATION Procedure revision date:

01/26/2000

Axle Shaft

Removal


2. Remove the axle shaft bolts. • Place a drain pan under the rear hub.

3. Remove the axle shaft (4234).

4. Inspect the following components: • The O-ring for damage. Replace as necessary. • The axle shaft for cracked material around the holes or oversized holes. Replace

as necessary.

Installation

1. NOTE: Lubricate the O-ring with Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.

Follow the removal procedure in reverse order.




01/26/2000

Hub

Special Tool(s)

Socket, Wheel Hub Nut (F-350 only) 205-282 (T88T-4252-A)

Removal

All vehicles

1. Remove the tire and wheel assembly. For additional information, refer to Section 204-04.

2. Remove the anchor plate. For additional information, refer to Section 206-04.

3. Remove the axle shaft (4234). For additional information, refer to Axle Shaft in this section.

F-350

4. NOTE: Make sure that the drive tangs on the special tool engage the four slots of the hub nut.

Using the special tool, remove the hub nut (1124).

F-450 and F-550

5. Using a suitable socket, remove the hub nut (1A124).

All vehicles

6. Remove the outer rear wheel bearing (1240).

7. Remove the rear hub and brake disc assembly.

8. Remove the bolts and separate the rear hub (1109) from the rear brake disc (2C026).

9. Inspect the rear hub for the following: • Cracks and damage around the bolt holes. • Oversized holes.

Installation

1. WARNING: Install a new rear hub seal (1175) after removing the rear hub from the axle. A damaged or worn seal can permit bearing lubricant to reach the

brake linings, resulting in ineffective brake operation. Failure to follow these instructions may result in personal injury.

CAUTION: Clean and remove any dirt or foreign material in the rear hub bolt holes.

Install a new rear hub seal. For additional information, refer to Bearings, Cups and Seals in this section.

2. Position the rear brake disc on the rear hub and install the bolts.

3. CAUTION: Thoroughly clean the spindle. Wrap the spindle threads with electrician's tape to prevent damage while installing the rear hub and brake disc assembly.

CAUTION: Lightly coat the spindle and pack each rear wheel bearing with Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.

Prepare the spindle for rear hub installation.

4. Slide the rear hub and brake disc assembly over the axle housing spindle. • Remove the electrician's tape.

5. Install the outer rear wheel bearing.

6. Start the hub nut making sure that the tab aligns correctly in the keyway prior to thread engagement.

7. NOTE: The following hub nut tightening sequence will prevent side-to-side end play of the hub and brake disc assembly.

NOTE: Apply inward pressure to the socket to separate the ratcheting components of the hub nut.

To adjust the bearings, tighten the nut to specification.

8. Back off the nut 90 degrees.

9. Tighten the nut to specification.

• To verify that there is no side-to-side end play, attach a magnetically mounted dial indicator to the spindle end and place the dial indicator tip on the outboard surface of the hub. Check for side-to-side end play.

• Final bearing adjustment has zero end play. The maximum torque to rotate the hub is 2.3 Nm (20 lb-in) when end play is zero.

10. Install the axle shaft (4234). For additional information, refer to Axle Shaft in this section.

11. Install the anchor plate. For additional information, refer to Section 206-04.

12. Install the tire and wheel assembly. For additional information, refer to Section 204-04.




01/26/2000


Special Tool(s)

Adapter for 303-224 (Handle) 205-153 (T80T-4000-W)

Drawbar, Rear Axle 205-098 (T75T-1176-A) (Dana 80)

Installer, Wheel Hub Inner Bearing Cup 205-442 (Dana S135)

Installer, Wheel Hub Outer Bearing Cup 205-444 (Dana S135)

Installer, Wheel Hub Inner Oil Seal 205-445 (Dana S135)

Installer, Rear Wheel Hub Bearing Cup 205-278 (T88T-1175-C) (Dana 80)

Remover, Wheel Hub Inner Bearing Cup 205-441 (Dana S135)

Remover, Wheel Hub Outer Bearing Cup 205-443 (Dana S135)

Remover, Rear Wheel Hub Bearing Cup 205-275 (T88T-1175-A) (Dana 80)

Remover, Rear Wheel Hub Bearing Cup 205-277 (T88T-1175-B) (Dana 80)

Removal

1. Remove the rear hub and brake disc assembly. For additional information, refer to Hub in this section.

2. Remove the rear hub seal (1175) and the inner rear wheel bearing (1244). Discard the rear hub seal.

3. If not done previously, remove the bolts and separate the rear hub (1109) from the brake disc.

4. Clean all the old grease and axle lubricant out of the rear hub.

5. Remove the inner and outer bearing cups. 1. For model 80, use special tools 205-277 and 205-153 to remove the inner bearing

cup. For model S135, use special tools 205-441 and 205-151 to remove the inner bearing cup.

2. For model 80, use special tools 205-275 and 205-153 to remove the outer bearing cup. For model S135, use special tools 205-443 and 205-153 to remove the outer bearing cup.

6. Clean the following components: • The rear axle housing spindle • All the old grease and axle lubricant from the rear hub • The rear wheel bearings and cups

7. Inspect the bearing races and rollers for pitting, galling or erratic wear patterns. Check the rollers for end wear. Discard the bearings, is necessary.

1. A typical new bearing roller

2. A worn bearing roller

Installation

Model 80

1. Using the special tools 205-098 and 205-278, install the inner and outer bearing cups. • Check if a 0.038-mm (0.0015-inch) feeler gauge can be inserted between the cups

and the rear hub at any point around each cup. Reseat the bearing cups, if necessary.

Model S135

2. Install the inner and outer bearing cups. 1. Use special tools 205-442 and 205-153 to install the inner bearing cups.

2. Use special tools 205-444 and 205-153 to install the outer bearing cups.

• Check if a 0.038-mm (0.0015-inch) feeler gauge can be inserted between the cups and the rear hub at any point around each cup. Reseat the bearing cups, if necessary.

All axles

3. Install the inner rear wheel bearing in the rear hub.

4. Install a new rear hub seal. • For model 80, use a suitable seal installer. • For model S135, use special tools 205-445 and 205-153.

5. Position the rear brake disc on the rear hub and install the bolts.

6. Install the rear hub and brake disc assembly. For additional information, refer to Hub in this section.

SECTION 205-02D:

Rear Drive Axle/Differential — Ford 10.50-Inch Ring Gear

SPECIFICATIONS



Description



IN-VEHICLE REPAIR

Axle Shaft

Drive Pinion Flange

Pinion Seal

Differential Housing Cover

Drive Pinion

Differential Case


Axle Assembly


Differential Case and Ring Gear—One Piece, Conventional

Differential Case and Ring Gear—Two-Piece, Conventional

Differential Case and Ring Gear—One-Piece, Traction-Lok

Differential Case and Ring Gear—Two-Piece, Traction-Lok




01/26/2000


Item Specification

Lubricants and Sealants

SAE 75W-140 Synthetic Rear Axle Lubricant F1TZ-19580-B WSL-M2C192-A

Additive Friction Modifier C8AZ-19B546-A EST-M2C118-A


Clear Silicone Rubber D6AZ-19562-AA ESB-M4G92-A

Threadlock and Sealer E0AZ-19554-AA WSK-M2G351-A5

Backlash Specifications


Backlash Between Ring Gear and Pinion Teeth 0.203-0.381 (0.008-0.015) maximum 0.305-0.381 (0.012-0.015) preferred

Ring Gear Maximum Backlash Variation Between Teeth 0.102 (0.004)

Rotational Torque Ranges


Pinion bearing preload (used pinion bearing) 0.9-1.5Nm (8-14 lb-in)

Pinion bearing preload (new pinion bearing) 1.8-3.3Nm (16-29 lb-in)

Driver handle 2.2Nm (20 lb-in)

Initial minimum breakaway torque (Traction-Lok®) 27Nm (20lb-ft)

Clearance Specifications


Differential Case Maximum Runout 0.076 (0.003)

Pinion Flange Maximum Radial Runout in Assembly 0.305 (0.012 T.I.R.)

RABS Sensor Air Gap 0.127-1.143 (0.005-0.045)


Description Nm lb-ft lb-in

Differential bearing cap bolt 119 88 —

Differential pinion shaft lock bolt 30 23 —

Oil filler plug 20-40 15-30 —

Rear axle housing vent 11-24 8-18 —

Rear brake hose 15-20 12-15 —

Axle housing cover bolts 38-52 29-39 —

Rear spring plate nuts 251 186 —

Ring gear bolts 136-163 101-120 —

Shock absorber bolts 63 47 —

Traction-Lok® clutch gauge nut 6.7 — 60

Brake junction block retainer nut 18 14 —

2-piece differential case half retaining bolts 122 90 —




01/26/2000


Ford 10.50-Inch Axle, Single Rear Wheel

Ford 10.50-Inch Axle, Dual Rear Wheel

Rear Axle — 10.50-Inch Ring Gear, Traction-Lok®


1 — Rear axle identification tag (Part of 4001)

2 4346 Differential housing cover bolt


4 4241 Differential pinion shaft lock bolt

5 391973-S1300 Differential case bolt






11 4067 Differential bearing shim



14 4216 Ring gear bolt

15 4204 Differential case


17 4209 Ring gear and pinion

18 4663 Drive pinion bearing adjustment shim

19 — Bearing cap and bolt (part of 4010)

20 4630 Pinion bearing— (inner)

21 4628 Inner axle pinion bearing cup

22 9E731 RABS sensor

23 4616 Outer pinion bearing cup

24 4662 Collapsible spacer

25 4621 Pinion bearing (outer)

26 4670 Rear axle drive pinion shaft oil slinger

27 4676 Rear axle drive pinion seal


29 389546-S100 Pinion nut

30 1244 Rear wheel bearing inner cone and roller

31 1177 Wheel bearing oil seal

32 1107 Lug bolt

33 4234 Axle shaft

34 N811648-S100 Axle shaft nut

35 1012 Lug nut

36 2C026 Rear disc brake rotor

37 1109 Rear hub

38 390258-S Gasket

39 1240 Bearing

40 1A034 Hub and bearing cup

41 1113 Rear brake hub and drum (DRW only)

42 4947 Differential clutch pack

43 4A324 Rear axle differential clutch shim

44 4214 Differential clutch spring

45 390943-S100 Filler plug

46 4010 Rear axle housing

47 2209 Brake adapter plate

Rear Axle — 10.50-Inch Ring Gear, Conventional


1 — Rear axle identification tag (Part of 4001)

2 4346 Differential housing cover bolt


4 4241 Differential pinion shaft lock bolt

5 391973-S1300 Differential case bolt






11 4067 Differential bearing shim



14 4216 Ring gear bolt

15 4204 Differential case


17 4209 Ring gear and pinion

18 4663 Drive pinion bearing adjustment shim

19 — Bearing cap and bolt (part of 4010)

20 4630 Pinion bearing— (inner)

21 4628 Inner axle pinion bearing cup

22 9E731 RABS sensor

23 4616 Outer pinion bearing cup

24 4662 Collapsible spacer

25 4621 Pinion bearing (outer)

26 4670 Rear axle drive pinion shaft oil slinger

27 4676 Rear axle drive pinion seal


29 389546-S100 Pinion nut

30 1244 Rear wheel bearing inner cone and roller

31 1177 Wheel bearing oil seal

32 1107 Lug bolt

33 4234 Axle shaft

34 N811648-S100 Axle shaft nut

35 1012 Lug nut

36 2C026 Rear disc brake rotor

37 1109 Rear hub

38 390258-S Gasket

39 1240 Bearing

40 1A034 Hub and bearing cup

41 1113 Rear brake hub and drum (DRW only)

42 390943-S100 Filler plug

43 4010 Rear axle housing

44 2209 Brake adapter plate

Description

The Ford 10.50-inch rear axle assembly is an integral type housing, hypoid gear design with the centerline of the ring gear set below the pinion centerline.

The hypoid ring gear and pinion consists of a 10.50-inch diameter ring gear and an overhung drive pinion. The pinion is positioned by selected pinion shims and supported by two opposed tapered roller bearings. Pinion bearing preload is adjusted by the pinion nut and a collapsible spacer.

The rear axle housing consists of a cast center section with two steel tubes and a stamped steel rear cover. The differential housing cover uses a silicone sealant as a gasket.

The differential case is a one or two-piece design depending upon the application. The differential pinion shaft in the one-piece differential case design (2-pinion) is retained with a threaded bolt. The two-piece differential case 3-pinion spider is retained by the case halves which are bolted together.

The rear axle drive pinion receives its power from the engine through the transmission and driveshaft. The drive pinion rotates the differential case through engagement with the ring gear, which is bolted to the case outer flange.

Inside the 2-piece differential case, three differential pinion gears are mounted on a three-post shaft. Inside the 1-piece differential case, two differential pinion gears are mounted on a straight shaft. These differential pinion gears are engaged with the differential side gears to which the axle shafts are splined. Therefore, as the differential case turns, it rotates the axle shafts and rear wheels. When it is necessary for one wheel and axle shaft to rotate faster than the other, the faster turning differential side gear causes the differential pinion gears to roll on the slower turning differential side gear to allow differential action between the two axle shafts.

The 10.50-inch rear axle uses SAE 75W-140 Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.




01/26/2000





IN-VEHICLE REPAIR Procedure revision date:

01/26/2000

Axle Shaft

For additional information, refer to Section 205-02E.




01/26/2000

Drive Pinion Flange

Special Tool(s)

2-Jaw Puller 205-D026 (D80L-1002-L) or Equivalent

Companion Flange Replacer 205-233 (T85T-4851-AH)

Flange Holder 205-012 (T57T-4851-B)

Removal

1. NOTE: The rear wheels and brake calipers must be removed to prevent brake drag during drive pinion bearing preload adjustment.

Remove the rear brake calipers. For additional information, refer to Section 206-04.

2. Remove the driveshaft (4602). For additional information, refer to Section 205-01.

3. Install a Nm (inch-pound) torque wrench on the pinion nut, and record the rotational torque required to maintain rotation of the pinion through several revolutions.

4. CAUTION: After removal of the pinion nut, discard it. A new nut must be used for installation.

Use the Flange Holder to hold the pinion flange while removing the pinion nut.

5. Mark the pinion flange in relation to the drive pinion stem to ensure proper alignment during installation.

6. Use the 2-Jaw Puller to remove the pinion flange.

Installation

1. Lubricate the pinion flange splines. • Use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or

equivalent meeting Ford specification WSL-M2C192-A.

2. NOTE: Disregard the scribe marks if a new pinion flange is being installed.

Align the pinion flange with the drive pinion shaft.

3. With the pinion flange in place in the rear axle housing (4010), install the pinion flange using the Companion Flange Replacer.

4. Position the new pinion nut.

5. CAUTION: Under no circumstances is the pinion nut to be backed off to reduce preload. If reduced preload is required, a new collapsible spacer and pinion nut must be installed.

Use the Flange Holder to hold the pinion flange while tightening the pinion nut.

• Tighten the pinion nut, rotating the pinion occasionally to make sure the cone and roller bearings are seating properly. Take frequent cone and roller bearing torque preload readings until the original recorded preload reading is obtained by rotating the pinion with a Nm (inch-pound) torque wrench.

• If the original recorded preload is lower than specifications, tighten to the appropriate specification for used bearings. If the preload is higher than specification, tighten the nut to the original reading as recorded. Refer to Torque Specifications in this section.


7. Install the brake calipers. For additional information, refer to Section 206-04.




01/26/2000

Pinion Seal

Special Tool(s)

Pinion Seal Replacer 205-208 (T83T-4676-A)

Removal

1. Remove the pinion flange. For additional information, refer to Drive Pinion Flange in this section.

2. Force up on the metal flange of the rear axle drive pinion seal (4676). Install gripping pliers to the seal flange and strike with a hammer until the rear axle drive pinion seal is removed.

Installation

1. Lubricate the new pinion seal. • Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification

ESA-M1C75-B.

2. CAUTION: If the rear axle drive pinion seal becomes misaligned during installation, remove the rear axle drive pinion seal and replace it with a new seal.

Use the Pinion Seal Replacer to install the rear axle drive pinion seal.

3. Install the pinion flange. For additional information, refer to Drive Pinion Flange in this section.




01/26/2000


Removal


2. Remove the differential housing cover (4033). 1. Remove the 12 differential housing cover bolts, and drain the lubricant from the

rear axle housing (4010).

2. Remove the differential housing cover.

Installation

1. CAUTION: Make sure the machined surfaces on both the rear axle housing and the differential housing cover are clean and free of oil before applying the new silicone sealant. The inside of the rear axle (4001) must be covered when cleaning the machined surface to prevent contamination.

Clean the gasket mating surface of the rear axle and the differential housing cover.

2. Apply a new, continuous bead of sealant to the differential housing cover. • Use Clear Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford

specifications ESB-M4G92-A.

3. NOTE: The differential housing cover must be installed within 15 minutes of application of the silicone, or new sealant must be applied. If possible, allow 1 hour before filling with lubricant to ensure the silicone sealant has properly cured.

Install the differential housing cover and tighten the differential housing cover bolts.

4. NOTE: Service refill capacities are determined by filling the rear axle with the specified lubricant to the specified level below the bottom of the filler hole.

Fill the rear axle with specified lubricant, and install the filler plug.

• For Traction-Lok® axles, first fill the rear axle with 236.5 ml (8 ounces) of specified Ford Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A.





01/26/2000


Removal


2. Remove the differential housing cover (4033). 1. Remove the 12 differential housing cover bolts, and drain the lubricant from the

rear axle housing (4010).


Installation

1. CAUTION: Make sure the machined surfaces on both the rear axle housing and the differential housing cover are clean and free of oil before applying the new silicone sealant. The inside of the rear axle (4001) must be covered when cleaning the machined surface to prevent contamination.



specifications ESB-M4G92-A.

3. NOTE: The differential housing cover must be installed within 15 minutes of application of the silicone, or new sealant must be applied. If possible, allow 1 hour before filling with lubricant to ensure the silicone sealant has properly cured.

Install the differential housing cover and tighten the differential housing cover bolts.

4. NOTE: Service refill capacities are determined by filling the rear axle with the specified lubricant to the specified level below the bottom of the filler hole.

Fill the rear axle with specified lubricant, and install the filler plug.

• For Traction-Lok® axles, first fill the rear axle with 236.5 ml (8 ounces) of specified Ford Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A.





02/14/2003

Differential Case

Special Tool(s)


Remover, Differential Carrier Bearing 205-S419 (Forcing Screw)


Installer, Differential Shim 205-228 (T85T-4067-AH)

Collets, Differential Carrier Bearing 205-430 (Part of 205-S419)

Retaining Ring, Differential Carrier Bearing 205-431 (Part of 205-S419)

Step Plate, Differential Carrier Bearing 205-432 (Part of 205-S419)

Removal


2. Remove the differential housing cover. 1. Remove the 12 differential housing cover bolts and drain the lubricant from the

rear axle housing.


3. Remove the axle shafts. For additional information, refer to Axle Shaft in this section.

4. Wipe the lubricant from the internal working parts, and visually inspect the parts for wear or damage.

5. Rotate the differential case to see if there is any roughness which would indicate damaged bearings or gears.

6. NOTE: There is a space between the anti-lock speed sensor ring and the ring gear for measuring ring gear backface runout.

Positioning the special tool, inspect ring gear backlash and ring gear backface runout.

7. CAUTION: Mark the position of the bearing caps, as arrows may not be visible. The bearing caps must be installed in their identical locations and positions.

Loosen the differential case.

1. Remove the bearing cap bolts.

2. Remove the bearing caps.

8. To simplify the installation, fabricate two differential case retaining straps from metal stock as shown.

9. WARNING: Be careful not to allow the differential case to fall.

CAUTION: Place a wood block between the pry bar and the rear axle housing to protect the machined surface from damage.

Use the pry bar and the wood block to remove the differential case from the rear axle housing.

10. Remove the ring gear bolts.

11. CAUTION: Care should be taken not to damage the ring bolt hole threads.

NOTE: The anti-lock speed sensor ring cannot be reused once removed.

Insert a punch in the bolt holes. Drive off the ring gear and, if necessary, the anti-lock speed sensor ring.

12. Install the differential case without the ring gear. 1. Position the differential case assembly, including bearing clips and shims, in the

housing.

2. Install the differential bearing caps.

3. Install the differential bearing cap bolts.

13. NOTE: Rotate the differential case to make sure the differential bearings are properly seated.

NOTE: If runout is within specification, install a new ring gear and pinion. If 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, replace both the differential case and the differential bearings.

Measure the differential case runout by rotating the differential case.

14. Remove the differential case from the rear axle housing, and prepare to remove the differential bearings.

1. Position the Step Plate.

2. Position the Carrier Bearing Remover (Forcing Screw) and the Remover and Replacer Tube.

3. Position the Side Carrier Bearing Collets.

15. Position the special tool.

16. Using two wrenches, remove the differential bearing. • Repeat the procedure for the other differential bearing.

17. Using the special tool, install the new differential bearings on the differential case.

18. Measure the differential case runout without the ring gear. • Check the case runout again with the new differential bearings. If the runout is

now within the specification shown, use the new differential bearings for assembly. If the runout is still excessive, the differential case is damaged and must be replaced.

Installation

All vehicles

1. Press the ring gear and, if removed, a new anti-lock speed sensor on the differential case.

2. Install the ring gear bolts. • Apply Stud and Bearing Mount E0AZ-19554-BA or equivalent meeting Ford

specification WSK-M2G349-A1 to the ring gear bolts.

3. With the pinion depth set and the pinion installed, place the differential case in the rear axle housing.

• Install a shim on the left side as shown in the illustration.

4. CAUTION: The bearing caps must be installed in their original locations and positions.

NOTE: Apply pressure toward the left side to make sure the left bearing is seated.

Install the left bearing cap, and loosely install the bearing cap bolts.

5. Install progressively larger shims on the right side until the largest shim selected can be assembled by hand.

6. Install the right side bearing cap, and tighten the bolts.

7. Rotate the differential case to make sure it rotates freely.

Measuring backlash

8. Using the special tool, measure ring gear backlash. • If the backlash is within specification, go to Backlash within specification in this

procedure. The specification shown is the full allowable range. For the preferred range, refer to Specifications in this section.

• If a zero backlash condition occurs, go to Zero backlash in this procedure. • If the backlash is not within specification, go to Backlash not within specification

in this procedure.

Zero backlash

9. If a zero backlash condition occurs, add a 0.50 mm (0.020 inch) shim to the RH side and subtract 0.50 mm (0.020 inch) from the LH side to allow backlash indication. Check backlash. Repeat Step 8.

Backlash Change Required Thickness Change Required

mm Inch mm Inch

0.025 0.001 0.050 0.002

0.050 0.002 0.050 0.002

0.076 0.003 0.101 0.004

0.101 0.004 0.152 0.006

0.127 0.005 0.152 0.006

0.152 0.006 0.203 0.008

0.177 0.007 0.254 0.010

0.203 0.008 0.254 0.010

0.228 0.009 0.304 0.012

0.254 0.010 0.355 0.014

0.279 0.011 0.355 0.014

0.304 0.012 0.406 0.016

0.330 0.013 0.457 0.018

0.335 0.014 0.457 0.018

0.381 0.015 0.508 0.020

10.

Backlash not within specification

10. To increase or decrease backlash, remove the bearing caps, and install a thicker shim and a thinner shim as shown.

• If backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness on the other differential bearing shim by the same amount.

11. Install the bearing caps and bearing cap bolts.

12. Rotate the differential several times to make sure the differential bearings are properly seated.

13. Using the special tool, recheck the backlash. • If backlash is within specification, go to Backlash within specification in this

procedure. If not, repeat Step 8. • The specification shown is the full allowable range. For the preferred range, refer

to Specifications in this section.

Backlash within specification

14. Remove the bearing caps and bolts. • To establish differential bearing preload, increase both left and right shim sizes by

the specification shown in the illustration.

• Using the special tool, ensure the differential bearing shims are fully seated and the assembly turns freely.

15. Install the bearing caps and bearing cap bolts.

16. Using the special tool, verify the backlash. • The specification shown is the full allowable range. For the preferred range, refer

to Specifications in this section. • For further adjustments, refer to Section 205-00.

17. Install the axle shafts; for additional information, refer to Axle Shaft in this section.

18. CAUTION: Make sure the machined surfaces on both the rear axle housing and the differential housing are clean and free of oil before applying the new silicone sealant. The inside of the rear axle must be covered when cleaning the machined surface to prevent contamination.



Specifications ESB-M4G92-A.




01/26/2000

Axle Assembly

Removal

1. Raise the vehicle on a hoist. For additional information, refer to Section 100-02.

2. Remove the wheels and tires. For additional information, refer to Section 204-04.


4. Disconnect the rear anti-lock brake sensor.

5. NOTE: Make sure the parking brake control is fully released.

Release the tension on the parking brake system.

1. Have an assistant pull the front parking brake cable and conduit to its full range.

2. Insert a suitable retainer.

6. Disconnect the parking brake cable at the parking brake lever.

7. Remove the vent hose at the brake hose junction block.

8. Remove the brake hose junction block from the rear axle housing and let it hang.

9. Remove the brake lines from the rear axle housing but not from the disc brake calipers and let the tubing hang.

10. Remove the disc brake calipers from the rear disc brake rotors and wire them aside. Refer to Section 206-04.

11. WARNING: Strap the axle securely to the jack.

Use a suitable transmission jack to support the axle.

12. Remove the lower shock absorber nuts and bolts.

13. NOTE: Once the rear spring plate nuts and bolts are removed, they must be replaced.

Remove the rear spring plate U-bolts and nuts.

14. Lower the axle from the vehicle.

Installation

1. Follow the removal procedure in reverse order. • Install the brake calipers. For additional information, refer to Section 206-04.



DISASSEMBLY AND ASSEMBLY Procedure revision date:

01/26/2000

Differential Case and Ring Gear—One Piece, Conventional

Special Tool(s)


Disassembly

1. Remove the differential case. For additional information, refer to Differential Case in this section.


3. Insert a punch in the bolt holes and drive the ring gear off.

4. NOTE: The anti-lock speed sensor ring cannot be reused once removed.

Remove the anti-lock speed sensor ring.

5. If required, remove the differential bearings. For additional information, refer to Differential Case in this section.

6. Remove the differential pinion shaft lock bolt and the differential pinion shaft.

7. Rotate and remove the differential pinion gears and differential pinion thrust washers.

8. Remove the differential side gears and the differential side gear thrust washers.

Assembly

1. Position the differential side gear thrust washers on the differential side gears. • Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification

ESA-M1C75-B to lubricate the differential side gear thrust washers and the differential side gear journals.

2. Position the differential side gears.

3. Assemble the differential pinion thrust washers and the differential pinion gears. • Lubricate with Premium Long-Life Grease XG-1-C or equivalent meeting Ford

specification ESA-M1C75-B.

4. Engage the differential pinion gears opposite the differential side gears.

5. Rotate the differential pinion gears to align the differential pinion shaft bore.

6. CAUTION: If a new pinion shaft lock bolt is not available, use Stud and Bearing Mount E0AZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 and tighten to specification.

Insert the differential pinion shaft, and install a new differential pinion shaft lock bolt.

7. Using the special tool, install the differential bearings.

8. Press the new anti-lock speed sensor ring and the ring gear on the differential case.

9. Install the ring gear bolts and tighten. • Apply Stud and Bearing Mount E0AZ-19554-BA or equivalent meeting Ford

specification WSK-M2G349-A1 to the ring gear bolts.

10. Install the differential case. For additional information, refer to Differential Case in this section.




01/26/2000

Differential Case and Ring Gear—Two-Piece, Conventional

Special Tool(s)

Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A)

Preload Gauge, Differential Clutch 205-447

Disassembly

1. Remove the differential case (4204). For additional information, refer to Differential Case in this section.


3. Insert a punch in the bolt holes and drive off the ring gear.

4. CAUTION: The anti-lock speed sensor ring cannot be reused once removed.

NOTE: Remove the anti-lock speed sensor ring only if required.

Remove the anti-lock speed sensor ring.

5. Position the special tool in a vise.

6. Position the differential case on the special tool.

7. Index mark the differential case halves.

8. NOTE: Attach the special tool with a bolt and nut.

Install the special tool on the differential case as shown and loosen the differential case bolts.

9. Remove the differential case bolts.

10. Remove the right differential case half and differential side gear (4236).

11. Remove the differential pinion shaft (4211) and differential pinion gears (4215).

12. Remove the left differential side gear and the differential side gear thrust washers (4228).

Assembly

1. Position left differential case half (ring gear side) on the special tool.

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

3. Lubricate the differential pinion gears, pinion gear thrust washers and the differential pinion shaft with Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.

4. Install the left differential side gear.

5. Install the differential pinion shaft and the differential pinion gears.

6. Position the right differential case half with the index marks aligned.

7. Position the differential case retaining bolts.

8. NOTE: Use the special tool as shown to keep the differential case from turning.

Tighten the retaining bolts.

9. Press the new anti-lock speed sensor ring, if removed, and the ring gear on the differential case.

10. NOTE: Apply Stud and Bearing Mount E0AZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to the ring gear bolts.

Install the ring gear bolt and tighten.





01/26/2000

Differential Case and Ring Gear—One-Piece, Traction-Lok

Special Tool(s)

Feeler Gauge Set 303-D027 (D81L-4201-A) or equivalent

Rotator, Differential 205-246 (T86T-4205-A)

Rotator, Limited Slip Differential 205-DS059 (D83T-4205-C) or equivalent

Step Plate 205-D019 (D80L-630-8) or equivalent

Gauge, Differential Clutch 205-135 (T80P-4946-A)

Gauge, Differential (Traction-Lok) 205-380 (T97T-4946-B)



Disassembly

1. Remove the differential case (4204); for additional information, refer to Differential Case in this section.

2. NOTE: The differential bearings (4221) need not be removed to overhaul the Ford limited slip differential. If bearing removal is required; for additional information, refer to Differential Case in this section.

NOTE: The anti-lock speed sensor ring cannot be reused once removed.

Remove the differential pinion shaft lock bolt, and remove the differential pinion shaft (4211).

• If required, remove the ring gear and anti-lock speed sensor ring.

3. NOTE: This tool does not have the 1/2-inch drive hole.

Install the special tool in a suitable vise.

4. Install the differential case on the tool.

5. Install the special tool in the bottom side gear bore. • Apply a small amount of grease to the centering hole of the special tool.

6. Install the nut in the upper differential side gear (4236). Hold the nut in position while installing the hex screw. Tighten the hex-head screw until contact is made with the Step Plate.

7. Insert a suitable dowel bar in the hole of the nut. Tighten the forcing screw to force the differential side gear away from the differential pinion gears (4215). The dowel bar is used to keep the nut from turning when the forcing screw is tightened.

8. WARNING: Keep fingers/hands away from pinion gears when rotating the differential case with the differential rotating tool.

NOTE: Differential pinion thrust washers (4230) cannot be removed independently of the differential pinion gears and so must be removed simultaneously with the differential pinion gears.

Insert the special tool in the pinion shaft bore, and turn the differential case to "walk" the differential pinion gears and differential pinion thrust washers out to the differential case windows.

9. Remove the differential pinion gears and differential pinion thrust washers.

10. Remove the differential side gears and differential clutch packs (4947), and tag them RIGHT and LEFT with the shim.

11. CAUTION: When separating the clutch plates and clutch discs, note the sequence in which they are disassembled. They must be reassembled in the same sequence.

CAUTION: Do not use acids or solvents when cleaning the differential clutch pack. Wipe components with a clean, lint-free cloth only.

Separate the differential clutch discs and clutch plates for cleaning and inspection. Refer to the disassembled view of the limited slip differential case in the Description and Operation portion of this section.

Assembly

1. Prelubricate each steel clutch plate and soak all friction plates in Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A for at least 15 minutes.

2. NOTE: Do not mix the differential clutch packs or shims from one side with the other.

NOTE: The Belleville spring is a dished plate.

Assemble the differential clutch packs (without the shims and Belleville springs) on the respective differential side gears.

3. Clamp the bolt head of the special tool in a vise. Install the differential clutch pack and the differential side gear (without the shim or the Belleville spring) on the gauge.

4. Position the special tool on top of the differential clutch pack.

5. Install the special tool over the disc and differential clutch pack.

6. Install the nut of the gauge over the top and base stud.

7. Use the Feeler Gauge Set and select the thickest blade that will enter between the tool and the differential clutch pack. The reading will be the thickness of the new clutch shim. Select the correct shim size, and remove the special tools.

Part Number Description

F75Z-4A324-DA 0.030 Inch

F75Z-4A324-EA 0.035 Inch

F75Z-4A324-FA 0.040 Inch

F75Z-4A324-GA 0.045 Inch

F75Z-4A324-HA 0.050 Inch

F75Z-4A324-JA 0.055 Inch

F75Z-4A324-KA 0.060 Inch

8.

8. Place the shim and Belleville spring on the differential clutch pack. • The dished or concave side of the Belleville spring must face up and against the

thrust face of the differential case. � Refer to the exploded view in the Description and Operation portion of

this section.

9. Insert the differential clutch packs with shims and Belleville springs and differential side gears into the differential case.

• Hold the upper differential clutch pack and side gear assembly in place to prevent it from falling out of the differential case.

10. NOTE: Apply a small amount of grease to the Step Plate bore.

NOTE: If necessary, insert the dowel bar in the nut bore to keep the nut from turning as the hex screw is tightened.

Assemble the forcing screw, nut and Step Plate to the differential case.

1. Position the Step Plate in the bottom side gear bore.

2. Position the nut in the top side gear bore and hold it in place.

3. Install the hex-head screw and tighten it two turns after it contacts the bottom Step Plate.

11. NOTE: Prelubricate both sides of the differential pinion thrust washers with SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.

NOTE: Make sure the differential pinion gears are 180 degrees apart so they will align correctly with the pinion shaft bore.

Position the differential pinion gears and differential pinion thrust washers in the window of the differential case so they mesh with the differential side gear teeth.

12. WARNING: Keep fingers/hands away from pinion gears when rotating the differential case with the differential rotating tool.

NOTE: It will probably be necessary to loosen or tighten the forcing screw to allow the differential pinion gears and differential side gears to rotate.

Insert the special tool into the pinion shaft bore, and turn the differential case. This will cause the differential pinion gears to engage the differential side gears and "walk" into the differential case. Rotate the differential case until the pinion mating shaft holes are lined up exactly with the holes in the differential pinion gears.

13. CAUTION: If a new pinion shaft lock bolt is not available, use Stud and Bearing Mount E0AZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 and tighten to specification.

Loosen the forcing screw, and remove the Step Plate and nut from the side gear bores. Install the differential pinion shaft in the differential case.

• Install a new differential pinion shaft lock bolt.

14. Replace the differential bearings, if removed.

15. Check the torque required to rotate one differential side gear. • Install the special tool with the (1/2-inch drive hole) as shown. • The initial break-away torque, if original clutch plates are used, must be within

specification. The rotating torque required to keep the differential side gear turning with new clutch plates may vary.

16. Install the ring gear and, if removed, a new anti-lock speed sensor ring on the differential case and tighten the retaining bolts.

17. Install the differential case; for additional information, refer to Differential Case in this section.




01/26/2000

Differential Case and Ring Gear—Two-Piece, Traction-Lok

Special Tool(s)

Gauge, Differential Clutch 205-135 (T80P-4946-A)

Gauge, Differential (Traction-Lok) 205-389 (T97T-4946–A)



Disassembly

1. Remove the differential case (4204); for additional information, refer to Differential Case in this section.


3. NOTE: The anti-lock speed sensor ring cannot be reused once removed.

Insert a punch in the bolt holes and drive the ring gear off.

• If necessary, remove the anti-lock speed sensor ring and discard it.

4. If the differential bearings (4221) require removal, refer to Differential Case in this section.

5. NOTE: This tool does not have the 1/2-inch drive hole.

Position the Traction-Lok Torque Tool Set in a vise.

6. Position the differential case on the Traction-Lok Torque Tool Set.

7. Index mark the differential case halves.

8. Remove the differential case bolts.

9. Remove the right differential case half and differential side gear (4236).

10. Remove the differential pinion shaft (4211) and differential pinion gears (4215).

11. Remove the differential pinion gears from the differential pinion shaft.

12. Remove both differential side gears and differential clutch packs (4947) from each differential case half.

13. Remove the Belleville spring and shim(s) from both differential clutch packs.

Assembly

1. Prelubricate each clutch disc and soak the clutch friction plate for at least 15 minutes in Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A.

2. CAUTION: Do not mix the differential clutch packs or shims from one side with the other.

NOTE: The Belleville spring is a dished plate.

Assemble the differential clutch packs (without the shims and Belleville springs) on the respective differential side gears.

3. NOTE: Use the Traction-Lok Clutch Gauge Mandrel for the procedure. Refer to the Special Tool(s) Chart.

Clamp the bolt head of the Traction-Lok Clutch Gauge in a vise.

• Install the differential clutch pack and the differential side gear (without the shim or the Belleville spring) on the gauge.

4. Position the Traction-Lok Clutch Gauge disc on top of the differential clutch pack.

5. Install the Traction-Lok Clutch Gauge housing over the disc and tighten the nut.

6. Use a feeler gauge and select the thickest blade that will enter between the tool and the differential clutch pack.

• The reading will be the thickness of the new clutch shim. • Select the correct shim size, and remove the Traction-Lok Clutch Gauge.

7. Place the selected shim and Belleville spring on the differential clutch pack. • The dished or concave side of the Belleville spring must be face up and against

the thrust face of the differential case.

8. Install the differential side gear and differential clutch pack into the left case half (ring gear side).

9. Position left differential case half on the Traction-Lok Torque Tool Set.

10. Lubricate the differential pinion gears, pinion gear thrust washers and the differential pinion shaft with Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.

• Install the differential pinion gears in the differential pinion shaft.

11. Install the differential pinion shaft and the differential pinion gears.

12. Install the right differential clutch pack and differential side gear into the right case half.

13. Position the right differential case half with the index marks aligned.

14. Install the retaining bolts and tighten.

15. Check the torque required to rotate one differential side gear. • Install the Traction-Lok Torque Tool Set with the 1/2-inch drive hole as shown. • The initial break-away torque, if the original clutch plates are used, must be

within specification. The rotating torque required to keep the differential side gear turning with new clutch plates may vary.

16. Install the ring gear and, if removed, a new anti-lock speed sensor ring on the differential case and tighten the retaining bolts.


SECTION 205-02E:

Wheel Hubs and Bearings — Full Floating Axle — Ford

SPECIFICATIONS






Axle Shaft


Hub




01/26/2000


Item Specification

SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B WSL-M2C192-A




Description Nm Lb-Ft

Axle Shaft Retaining Bolts 109 80

Hub Nuta — — a Refer to text.




01/26/2000


The full-floating rear axle features disc brakes. The disc brake calipers must be removed to remove rotors and hubs. The rotor on the single rear wheel design can be removed without removing the hub. Dual rear wheel axles require that the hub and rotor be removed as a unit.

Both DRW and SRW hubs feature a cartridge type seal that must be replaced anytime the hub is removed.

The rear hub is supported or floats on the axle spindle on two opposed tapered roller bearings. It is retained on the spindle by a ratcheting nut that is tabbed to a slot on the spindle.


1 — Spindle (Part of 4010)

2 1109 Hub

3 1244 Inner Bearing

4 1A124 Hub Nut (RH)

5 1A125 Hub Nut (LH)

6 4670 Slinger

7 1177 Hub Seal


1 N811648-S100 Axle Shaft Bolts

2 4234 Axle Shaft

3 2C026 Rotor (SRW)

4 2C026 Hub and Rotor (DRW)

5 1A124 Hub Nut (RH)

6 1A125 Hub Nut (LH)

7 1239 Outer Bearing Cup

8 1240 Outer Cone and Roller

9 1243 Inner Bearing Cup

10 1244 Inner Bearing

11 4670 Slinger

12 1177 Hub Seal

13 1A034 Rear Hub Assy (with Cups)

14 1109 Rear Hub Assy (Complete)

15 2209 Parking Brake Assy

16 390258-S O-Ring

17 W704709-S428 Wheel Studs




01/26/2000






01/26/2000






01/26/2000

Axle Shaft

Removal

1. NOTE: The wheels and tires do not have to be removed in order to remove the axle shafts.

Loosen and remove the retaining bolts.

2. Remove the axle shaft.

3. Inspect the axle shaft O-ring seal for cracks, nicks or wear and replace it if required.

Installation

1. Install the axle shaft.

2. NOTE: Coat the threads of the retaining bolts with Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1.

Install the retaining bolts and tighten.




01/26/2000

Axle Shaft

Removal

1. NOTE: The wheels and tires do not have to be removed in order to remove the axle shafts.

Loosen and remove the retaining bolts.

2. Remove the axle shaft.


Installation



Install the retaining bolts and tighten.




01/26/2000

Hub

Special Tool(s)

2-Jaw Puller 205-D026 (D80L-1002-L) or Equivalent

Ford Axle Locknut Socket 205-448

Step Plate 205-D018 (D80L-630-7) or Equivalent

Removal


2. Loosen the retaining bolts.

3. Raise the vehicle to the desired working height, keeping the axle parallel with the floor; for additional information, refer to Section 100-02.

4. Release the parking brake.

5. Remove the wheel(s); for additional information, refer to Section 204-04.

6. Remove the brake caliper and rotor on the single rear wheel axle; for additional information, refer to Section 206-04.

7. Remove the retaining bolts and axle shaft.

8. CAUTION: The hub nuts are right-hand thread (right hub) and left-hand thread (left hub). Each hub nut is stamped RH or LH.

Install the Ford Axle Locknut Socket so that the drive tangs of the tool engage the four slots in the hub nut.

9. CAUTION: Discard the hub nut if the hub nut comes apart during removal.

CAUTION: Under no circumstances are power tools to be used when performing these operations.

NOTE: The hub nut will ratchet during this operation.

Remove the hub nut (counterclockwise for right-hand thread; clockwise for left-hand thread).

10. Install the Step Plate.

11. Install the 2-Jaw Puller and loosen the rear hub to the point of removal.

12. CAUTION: Do not drop the outer hub bearing when removing the hub.

Remove the rear hub assembly.

13. CAUTION: Install a new hub seal each time the hub assembly is removed.

NOTE: The inner bearing is located behind the hub seal.

Pack each bearing and replace the hub seals; for additional information, refer to Bearings, Cups and Seals in this section.

14. CAUTION: Use extreme care not to scratch or gouge the seal or bearing surfaces.

If after hub removal, the hub seal or seal inner sleeve remains on the spindle, remove it as shown using the Step Plate and the 2-Jaw Puller.

15. Inspect the seal surface and inner shoulder for scratches and damage. • Remove all scratches, gouges or galling damage with #600 or finer crocus cloth.

Installation

1. NOTE: Clean the spindle thoroughly after removing the rear hub.

Coat the spindle with axle lubricant.

2. CAUTION: The hub bearings must be prelubed prior to installation.

Fill the hub cavity with 29.6 ml (1 oz) of SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.

3. CAUTION: Use extreme care not to damage the hub seal by allowing it to contact the spindle during installation.

NOTE: Coat the spindle and hub seal inside diameter with SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.

NOTE: Installing the rear hub in this manner causes the outer bearing to act as a pilot making the installation easier.

Push the rear hub and outer bearing onto the spindle as an assembly.

• Hold the outer bearing seated and use the bearing as a pilot.

4. CAUTION: Install a new hub nut if the hub nut comes apart during installation.

CAUTION: Make sure the hub nut tab is located in the keyway prior to thread engagement.

Install the hub nut on the spindle.

• Turn the hub nut clockwise for right-hand thread or counterclockwise for left-hand thread.

5. Position the Ford Axle Locknut Socket on the hub nut.

6. CAUTION: Under no circumstances are power tools to be used when performing these operations.

NOTE: The hub nut will ratchet as torque is applied.

Tighten the hub nut, rotating the rear hub occasionally while tightening.

7. Adjust hub nuts as follows: • For new bearings, ratchet back five teeth or notches (1/8 turn) on the hub nut.

Five notches must be felt during this operation in order to have performed it correctly.

• For used bearings, ratchet back seven teeth or notches (1/6 turn) on the hub nut. Seven notches must be felt during this operation to have performed it correctly.




Install and tighten the retaining bolts until they seat.

11. CAUTION: Remember, the last step of this procedure is to tighten the axle shaft bolts to specification, after the wheel lug nuts have been tightened.

Install the brake rotor and caliper on the single rear wheel axles; for additional information, refer to Section 206-04.

12. Install the wheels and tires but do not tighten the lug nuts to specification at this time.

13. Check the axle lubricant level; for additional information, refer to Section 205-02D.


15. Tighten the wheel lug nuts; for additional information, refer to Section 204-04.

16. Tighten the axle shaft retaining bolts.

SECTION 205-03:

Front Drive Axle/Differential

SPECIFICATIONS


Front Drive Axle and Differential


Front Drive Axle

GENERAL PROCEDURES

Axle and Differential Drain and Refill

IN-VEHICLE REPAIR

Drive Pinion Seal


Axle Assembly


Axle

Differential Case





Item Specification

Lubricants and Sealants

SAE 90 Premium Rear Axle Lubricant C2AZ-19580-F ESW-M2C105-A

High Temperature 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590-A

ESA-M1C198-A

Clear Silicone Rubber D6AZ-19562-AA ESB-M4G92-A or ESE-M4G195-A

Lubricant Fill Level Checks

Item Specification

Axle lubricant 2.8 liters (5.9 pints)

Backlash Specifications

Item Specification

Backlash between ring gear and pinion 0.13-0.20 mm (0.005-0.008 in)

Maximum ring gear backlash variation 0.05 mm (0.002 in)

Rotational Torque Ranges

Item Specification

Pinion bearing preloada b c d 1.7-3.4 Nm (15-30 lb-in)

a Never back off the pinion nut to reduce preload. If preload reduction is necessary, install a new collapsible spacer and pinion nut. b Take frequent pinion bearing torque preload readings. c For new pinion bearing installation, tighten the pinion nut to a rotating torque of 1.7-3.4 Nm (15-30 lb-in) (217-678 Nm [160-500 lb-ft]). d For original pinion bearing installation, the reading must be 0.56 Nm (5 lb-in) more than the initial reading taken during the disassembly procedure.



Pinion nuta b c d 217-678 160-500

Bolt retaining the front driveshaft to the front axle flange 35 26

Nut retaining the u-bolt to the axle 133 99

Nut and bolt retaining the trackbar to the axle 174 129

Bolt retaining the stabilizer bar bracket to the axle 47 35

Bolt retaining the differential bearing cap to the differential housing 109 80

Bolt retaining the differential housing cover to the differential housing 47 35

Bolt retaining the ring gear to the differential case (model 50)

136 100

Bolt retaining the ring gear to the differential case (model 60)

183 135

Fill plug 27 20 a Never back off the pinion nut to reduce preload. If preload reduction is necessary, install a new collapsible spacer and pinion nut. b Take frequent pinion bearing torque preload readings. c For new pinion bearing installation on model 50 and 60 axles, tighten the pinion nut to a rotating torque of 1.7-3.4 Nm (15-30 lb-in) (217-678 Nm [160-500 lb-ft]). d For original pinion bearing installation, the reading must be 0.56 Nm (5 lb-in) more than the initial reading taken during the disassembly procedure.




Front Drive Axle





Axle and Differential Drain and Refill

Special Tool(s)

Oil Suction Gun 303-D104 (D94T-9000-A) or equivalent

Material

Item Specification

SAE 90 Premium Rear Axle Lubricant C2AZ-19580-F

ESW-M2C105-A


2. Drain and refill the axle lubricant. 1. Remove the fill plug.

2. Using the special tool, remove the axle lubricant through the fill hole.

3. Fill the axle with the specified type and quantity of lubricant.

4. Install the fill plug.


SECTION 205-03: Front Drive

Axle/Differential 1999 F-Super Duty 250-550 Workshop

Manual


Drive Pinion Seal

Special Tool(s)

Holding Fixture, Drive Pinion Flange 205-012 (T57T-4851-B)


Remover, Drive Pinion Flange 205-018 (T65L-4851-B)


Material

Item Specification

SAE 90 Premium Rear Axle Lubricant C2AZ-19580-F

ESW-M2C105-A

Removal

1. With the vehicle in NEUTRAL, raise and support the vehicle. For additional information, refer to Section 100-02.

2. Index-mark the front driveshaft and the front axle flange to maintain driveline balance.

3. Disconnect the front driveshaft from the front axle flange, and position it aside. 1. Remove and discard the four bolts and two retainers.

2. Disconnect the front driveshaft from the front axle flange.

3. Tape the bearing cups to the spider to prevent them from falling off the spider.

4. Position the driveshaft aside.

4. Measure the pinion bearing torque preload. Record the reading. • Rotate the pinion with a Nm (lb-in) torque wrench. Record the torque necessary to

maintain rotation of the pinion through several revolutions.

5. Remove and discard the nut and washer. • Use the special tool to prevent the flange from turning while removing the nut.

6. NOTE: Index-mark the flange and the pinion shaft.

Using the special tool, remove the flange.

7. Using the special tools, remove the pinion seal. Discard the seal.

8. Clean and inspect the following: • The seal mounting surface. • The flange lugs and the flange end that contacts the bearing cone.

� Verify that the flange nut counterbore and the seal contact surfaces are smooth and free of nicks.

Installation

1. Using a suitable driver, install the pinion seal. • Lightly coat the pinion seal lip with lubricant.

2. CAUTION: Never use a metal hammer on the pinion flange or install the flange with power tools. If necessary, use a plastic hammer to tap on a tight fitting flange.

NOTE: Align the index marks.

Lightly coat the flange splines and seal mating area with lubricant, then install the flange with a new washer and nut.

3. CAUTION: Never back off the pinion nut to reduce preload. If preload reduction is necessary, install a new collapsible spacer and pinion nut.

Tighten the nut.

• Use the special tool to prevent the flange from turning while tightening the nut. Remove the special tool when taking pinion bearing torque preload readings.

• Take frequent pinion bearing torque preload readings. • The final reading must be 0.56 Nm (5 lb-in) more than the initial reading taken

during removal.

4. Connect the front driveshaft to the front axle flange. 1. Remove the tape from the bearing cups.

2. Connect the front driveshaft to the front axle flange.

3. Install the two new retainers and four new bolts.

5. Check and, if necessary, fill the axle with the specified lubricant. For additional information, refer to Specifications in this section.




Manual


Axle Assembly

Removal


2. Remove the disc brake calipers. 1. Remove the bolts.

2. Lift the disc brake caliper from the disc brake caliper anchor plate.

• Using mechanics wire, position the disc brake caliper aside.

3. Remove the disc brake pads. 1. Remove the disc brake pads.

2. Remove the front disc brake caliper anchor rail clips.

4. Disconnect the power vacuum hub hose from the knuckle, then disconnect the ABS sensor.

5. Remove the front stabilizer bar-to-axle retaining bolts.

6. If equipped, disconnect the steering damper at the axle. For additional information, refer to Section 211-03.

7. Disconnect the steering linkage at the steering knuckles, and position it aside. For additional information, refer to Section 211-03.

8. CAUTION: Index-mark the driveshaft to the companion flange to maintain proper driveline balance.

Disconnect the driveshaft at the front axle, and position it aside. For additional information, refer to Section 205-01.

• Wrap electrical tape around the bearing cups.

9. Disconnect the vent tube and plug the fitting.

10. NOTE: It is necessary to load the suspension to remove the trackbar. Load the springs by allowing most of the front vehicle weight to rest on the axle.

Support the axle with a suitable jack, and lower the vehicle enough to relieve the tension on the trackbar. Then, disconnect the trackbar at the axle, and position it aside.

• Relieve the load on the suspension after disconnecting the trackbar. • Leave the jack supporting the axle for removal from the vehicle.

11. Remove the U-bolts securing the axle to the springs.

12. Lower and remove the axle.

Installation


• Check and, if necessary, fill the axle with the specified lubricant. For additional information, refer to Specifications in this section.



Manual


Axle Assembly

Removal


2. Remove the disc brake calipers. 1. Remove the bolts.

2. Lift the disc brake caliper from the disc brake caliper anchor plate.

• Using mechanics wire, position the disc brake caliper aside.

3. Remove the disc brake pads. 1. Remove the disc brake pads.

2. Remove the front disc brake caliper anchor rail clips.

4. Disconnect the power vacuum hub hose from the knuckle, then disconnect the ABS sensor.

5. Remove the front stabilizer bar-to-axle retaining bolts.

6. If equipped, disconnect the steering damper at the axle. For additional information, refer to Section 211-03.

7. Disconnect the steering linkage at the steering knuckles, and position it aside. For additional information, refer to Section 211-03.

8. CAUTION: Index-mark the driveshaft to the companion flange to maintain proper driveline balance.

Disconnect the driveshaft at the front axle, and position it aside. For additional information, refer to Section 205-01.

• Wrap electrical tape around the bearing cups.

9. Disconnect the vent tube and plug the fitting.

10. NOTE: It is necessary to load the suspension to remove the trackbar. Load the springs by allowing most of the front vehicle weight to rest on the axle.

Support the axle with a suitable jack, and lower the vehicle enough to relieve the tension on the trackbar. Then, disconnect the trackbar at the axle, and position it aside.

• Relieve the load on the suspension after disconnecting the trackbar. • Leave the jack supporting the axle for removal from the vehicle.

11. Remove the U-bolts securing the axle to the springs.

12. Lower and remove the axle.

Installation


• Check and, if necessary, fill the axle with the specified lubricant. For additional information, refer to Specifications in this section.



Manual


Differential Case

Special Tool(s)

Puller, Drive Pinion/Differential Carrier 205-D036 (D81L-4220-A) or equivalent

Disassembly

1. CAUTION: Do not reuse the bearings after removing them from the differential case (4204).

Remove the differential bearings and the shims.

1. Place the differential (4026) into a vise with soft jaws.

2. Using the special tool, remove the differential bearing.

3. CAUTION: Discard any damaged shims at time of assembly.

Remove the differential bearing shims (4067).

� Wire the shims, the bearing cone, and the cup together. Identify from which side they were removed.

� Repeat the procedure for the opposite side.

2. CAUTION: Discard the bolts after removing them from the differential case.

CAUTION: Place shop towels under the ring gear to prevent ring gear damage.

Remove the ring gear.

1. Place the differential case into a vise with soft jaws.

2. Remove and discard all but four of the bolts. Leave four loosely assembled bolts spaced apart from each other.

3. Tap each bolt head alternately with a soft face hammer to loosen the ring gear. Remove the bolts and the ring gear. Discard the bolts.

3. Using a hammer and a small drift, drive out the differential pinion shaft lock pin (4241).

4. Remove the differential pinion shaft (4211).

5. Remove the differential pinion gears (4215) and thrust washers, and the differential side gears (4236) and thrust washers.

6. CAUTION: Always use new solvent when cleaning the bearings.

CAUTION: Do not spin dry the bearings with compressed air.

CAUTION: Oil the bearings immediately, to prevent rusting.

CAUTION: If upon inspection, any component has score marks/chips, thoroughly clean the differential housing.

Carry out the following inspection.

• Thoroughly clean all parts. • Inspect all parts for damage.

� Discard the complete differential if excessive wear is visible on all parts. � Discard both differential pinion gears and both differential side gears if

any one of these gears are worn/damaged. � Verify that the differential bearing bores are smooth. Remove any

nicks/burrs from the mounting surfaces of the differential housing.

Assembly

1. Place the differential case into a vise with soft jaws.

2. Apply axle and wheel bearing grease to the following. • The differential side gear thrust washers. • The differential side gear hubs and thrust faces. • The differential pinion thrust washers. • The differential pinion gears.

� Assemble the gears and their respective washers.

3. Lubricate the gears with lubricant, then install them into the differential case. • Install and hold the differential side gears and thrust washers in the differential

case. Then, install the differential pinion gears and thrust washers, and rotate them until the pinion shaft bore in the case and gears align.

� If hand rotation of the gears is not possible, install an axle shaft into the differential side gear, and turn the shaft with a pipe wrench.

� If necessary, use a drift to align the pinion shaft bores.

4. Install the differential pinion shaft, aligning the lock pin bore in the differential case and the pinion shaft.

5. Install the differential pinion shaft lock pin. • Peen the differential case metal over the lock pin, in two places, 90 degrees from

the slot in the lock pin.

6. On model 50 axles, assemble the ring gear to the differential case, and alternately and evenly tighten the new bolts.

7. On model 60 axles, assemble the ring gear to the differential case, and alternately and evenly tighten the new bolts.

8. Install the differential bearings only after determining the appropriate amount of differential bearing shims to install. For additional information, refer to Axle in this section.

40697115 ws manual 1999 f super duty s 1 g 00 gen info amp s2 susp driveline part 1 a

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