ford explorer rear axle dissasembly

205-00-1 205-00-1Driveline System

REMOVAL AND INSTALLATIONSpecial Tool(s)Differential Ring And Pinion — Rear

Step PlateAxle205-D061 (D83T-4205-C2) orequivalent

Special Tool(s)

Dial Indicator Gauge withHolding Fixture100-002 (TOOL-4201-C) orequivalent

Holding Fixture, Drive PinionFlange205-126 (T78P-4851-A)

Spreader, Differential Housing(Plate)205-335 (T93P-4000-A)

Protector, Drive Pinion Thread205-460

Holding Fixture, Transmission307-003 (T57L-500-B)

Installer, Drive Pinion BearingCup205-024 (T67P-4616-A)

Spreader, Differential Carrier205-001 (TOOL-4000-E) orequivalent

Adapter for 205-S127205-105 (T76P-4020-A3)

Gauge, Clutch Housing308-021 (T75L-4201-A)

Adapter for 205-S127205-110 (T76P-4020-A10)

2-Jaw Puller205-D072 (D97L-4221-A) orequivalent

Adapter for 205-S127205-129 (T79P-4020-A18)

(Continued)

(Continued)

Copyright 2003, Ford Motor CompanyLast updated: 8/22/2006 2004 Explorer/Mountaineer, 10/2003


REMOVAL AND INSTALLATION (Continued)

Special Tool(s) Special Tool(s)

Adapter for 205-S127 Installer, Drive Pinion Flange205-111 (T76P-4020-A11) 205-002 (TOOL-4858-E) or

equivalent

Adapter for 205-S127 Installer, Differential Side205-109 (T76P-4020-A9) Bearing

205-010 (T57L-4221-A2)

Gauge Tube, Drive PinionMaterial205-336 (T93P-4020-A)

Item Specification

Premium Long-Life ESA-M1C75-BGreaseXG-1-C

Threadlock and Sealer WSK-M2G351-A5TA-25Installer, Drive Pinion Bearing

Cone Stud and Bearing Mount WSK-M2G349-A1205-005 (T53T-4621-C) TA-27

Silicone Gasket and WSE-M4G323-A4SealantF7AZ-19554-EA

Ring and Pinion Marking —Compound

Plate, Bearing/Oil Seal —205-090 (T75L-1165-B)

Installer, Drive Pinion Oil Seal205-208 (T83T-4676-A)

(Continued)

2004 Explorer/Mountaineer, 10/2003



Item Part Number Description Item Part Number Description

8 — Differential ring gear (part of1 4067 Differential bearing shim4209)2 4222 Differential bearing cup

9 4221 Differential bearing3 4204 Differential case10 4033 Differential housing cover4 4216 Ring gear bolt11 4B416 Inboard CV joint stub shaft5 4230 Differential pinion gear thrust

pilot bearing housing sealwasher12 4B413 Inboard CV joint stub shaft6 4211 Differential pinion shaft

pilot bearing7 4241 Differential pinion shaft lock

13 4010 Differential housingbolt(Continued)

(Continued)




Item Part Number Description 3. CAUTION: Do not damage thealuminum differential housing while carrying14 4662 Differential drive pinion

collapsible spacer out these procedures.15 4670 Drive pinion shaft oil slinger Using the special tools, mount the differential16 4851 Pinion flange housing to a work bench.17 389546-S100 Pinion nut 1 Attach the special tools to the differential18 4859 Drive pinion oil seal deflector housing with 4 differential housing cover

bolts.19 4676 Drive pinion seal

20 4621 Drive pinion bearing 2 Attach the special tools together with 23/8-inch x 1-1/2-inch bolts.21 4616 Differential drive pinion

bearing cup

22 56187-S Differential bearing cap bolt

23 — Drive pinion gear (part of4209)

24 — Differential bearing cap (partof 4010)

25 4628 Drive pinion bearing cup

26 4630 Drive pinion bearing

27 4663 Drive pinion bearingadjustment shim

28 4A321 Differential clutch shim

29 — Differential clutch plate (partof 4947)

30 — Differential clutch disc (part 4. CAUTION: RH spreader set screwof 4947)

must not be adjusted further down than31 4236 Differential side gear flush or the spreader rocks and damages the32 4214 Differential clutch spring seal and the housing.33 4215 Differential pinion gear Install the special tool by placing the spreader34 4947 Differential clutch pack pins in the hole in the housing spreader35 390943-S100 Fill plug adapters.

Removal

1. Remove the rear axle assembly. For additionalinformation, refer to Rear Axle Assembly inthis section.

2. Remove the differential housing cover and drainthe lubricant.




5. Assemble the special tools. 7. CAUTION: Mark the position andlocation of the differential bearing caps as1 Install the special tool.the arrows may not be visible. Always install2 Attach the special tool and position the tipthe differential bearing caps in their originalin the housing spreader adapter hole.locations and positions.

Remove the differential bearing caps.

1 Remove the differential bearing cap bolts.

2 Remove the differential bearing caps.

6. CAUTION: Overspreading can damagethe differential housing.

NOTE: Tighten and loosen the differentialcarrier spreader screw to normalize the housingspreader adapters prior to taking the final dial 8. CAUTION: Use wood blocks to avoidindicator reading. damaging the differential housing.Spread the differential housing to the Remove the differential assembly.specification.

1 Position wood blocks at the top and bottom1 Adjust the special tool to zero. of the differential assembly.2 Tighten the screw until the differential 2 Pry the differential assembly and the

housing is spread to the specification. differential bearing shims out of thedifferential housing.3 Remove the special tool.

3 Remove the special tool.




9. Remove the 10 ring gear bolts.

14. Using the special tool, remove the pinionflange.

10. CAUTION: Do not damage the ringgear bolt hole threads.

Insert a punch in the ring gear bolt holes anddrive the differential ring gear off.

11. WARNING: The speed sensor ringcannot be reused once removed. Remove thespeed sensor ring only if damaged.

If necessary, remove the speed sensor ring.

12. Using the special tools, remove the differentialbearings.

15. Use a screwdriver to force up the metal flangeof the drive pinion oil seal. Install grippingpliers and strike with a hammer to remove thedrive pinion oil seal.

13. Using the special tool, hold the pinion flange toremove and discard the pinion nut.

16. Remove the drive pinion oil seal deflector,drive pinion oil seal slinger, the outer pinionbearing and the drive pinion collapsible spacer.




17. Using the special tool and a soft-faced hammer,remove the differential pinion gear from thedifferential housing.

2. NOTE: If a feeler gauge of the specificationshown can be inserted between a cup and thebottom of its bore at any point around the cup,the cup is not correctly seated.

18. Using a brass drift and a hammer, remove the Make sure the differential pinion bearing cupsdifferential drive pinion bearing cups from the are correctly seated.differential housing. Tap alternately on eachside of the cup to prevent them from cocking inthe bore.

Installation

1. Using the special tool, install the differentialdrive pinion bearing cups.

1 Position the bearing cups on the specialtool.

2 Position the special tool and the differentialdrive pinion bearing cups in the differentialhousing.

3 Tighten the special tool to fully seat thedifferential drive pinion bearing cups in thebores.




Item Part Number Description3. CAUTION: Use the same drive pinionbearings and the drive pinion bearing 5 205-110 Adapter for 205-S127adjustment shim from the drive pinion 6 4621 Outer (front) pinion bearingbearing adjustment shim selection procedure 7 205-111 Adapter for 205-S127for final assembly.

NOTE: Install new drive pinion bearings 4. NOTE: This step duplicates drive pinionwithout any additional lubricant since the bearing preload.anti-rust oil provides adequate lubricant without Thread the special tool onto the screw andupsetting the drive pinion bearing preload tighten to the specification.settings.

• Tighten to 2.2 Nm (20 lb-in).Install the new drive pinion bearings andspecial tools as shown.

5. CAUTION: Position the adapter so itdoes not contact the housing.

CAUTION: Offset the special tool toobtain an accurate reading.

Rotate the special tool several half turns to seatthe drive pinion bearings. Position the specialtool as shown.

Item Part Number Description

1 205-109 Adapter for 205-S127

2 205-105 Adapter for 205-S127

3 4630 Inner (rear) pinion bearing

4 205-129 Adapter for 205-S127(Continued)




6. Install the special tool.

1 Position the special tool on the differentialhousing differential bearing seat.

2 Install the differential bearing caps.

3 Install the differential bearing cap bolts.

X Tighten to 105 Nm (77 lb-ft).

11. CAUTION: Make sure the splines onthe drive pinion gear stem are free of burrs.If burrs are evident, remove them using afine crocus cloth.

Place a new differential drive pinion collapsiblespacer on the drive pinion gear stem against thepinion stem shoulder.

7. Use a drive pinion bearing adjustment shim as agauge for shim selection. Check the drivepinion bearing adjustment shim thicknessbetween the gauge block and the gauge tube. Aslight drag indicates correct shim selection.

12. Install the outer pinion bearing and the drivepinion oil seal slinger.

8. Remove all of the special tools.

9. Position the drive pinion bearing adjustmentshim and the inner pinion bearing on the drivepinion gear stem.

10. Using the special tools and a suitable press,firmly seat the drive pinion bearing adjustmentshim and inner pinion bearing on the drivepinion gear stem.




15. Position the pinion flange.13. CAUTION: Installation without thecorrect tool can result in early drive pinion 1 Lubricate the pinion flange splines withseal failure. grease.

2 Position the pinion flange.CAUTION: If the drive pinion sealbecomes misaligned during installation,remove it and install a new drive pinion seal.

NOTE: Coat the drive pinion seal lips withgrease.

Using the special tool, install the new drivepinion seal.

16. Using the special tool, install the pinion flange.

14. Install the drive pinion gear with the differentialdrive pinion collapsible spacer in thedifferential housing.




19. Press the left and right differential bearing on17. CAUTION: Do not, under anythe differential assembly.circumstance, loosen the pinion nut to reduce

drive pinion bearing preload. If it is 1 Position the differential bearing.necessary to reduce drive pinion bearing 2 Using the special tool, press the differentialpreload, install a new differential drive bearing on the differential assembly.pinion collapsible spacer and pinion nut.

CAUTION: Remove the special toolwhile taking drive pinion bearing preloadreadings with the Nm (lb-in) torque wrench.

Use the special tool to hold the pinion flangewhile tightening the pinion nut.

• Rotate the drive pinion gear occasionally tomake sure the drive pinion bearings seatcorrectly. Take frequent drive pinion bearingpreload readings by rotating the drive piniongear with a Nm (lb-in) torque wrench.

20. NOTE: If removed, press the speed sensor ringon with the differential ring gear.

Install the differential ring gear.

1 Place the differential ring gear on thedifferential assembly.

2 Hand-start 3 ring gear bolts to align theholes in the differential ring gear and thedifferential assembly.

3 Place the differential assembly anddifferential ring gear onto the press bedblocks with the differential ring gear teeth

18. Tighten the pinion nut to set the drive pinion facing downward.bearing preload. Refer to the torque

4 Press the differential ring gear into place.specification for drive pinion bearings in theSpecifications portion of this section.




21. Install the ring gear bolts after applying sealer 24. NOTE: Apply pressure toward the left side toto the bolt threads. make sure the left bearing cap is seated.

• Use stud and bearing mount. Install the left bearing cap and loosely installthe bearing cap bolts.• Tighten to 105 Nm (77 lb-ft).

25. NOTE: Apply pressure toward the left side to22. Install the differential assembly.make sure the left bearing cap is seated.

1 Position the differential bearing cups on theInstall progressively thicker differential bearingdifferential bearings.shims on the right side until the thickest

2 Lower the differential assembly in place. differential bearing shim can be inserted byhand.

23. Install a differential bearing shim of thethickness shown on the LH side of the 26. Install the right bearing cap and bolts.differential case.




27. Tighten the 4 differential bearing cap bolts. 30. Using the special tools, measure the differentialring gear backlash at 4 equally spaced points.• Tighten to 105 Nm (77 lb-ft).1 Attach the special tool.

2 Position the special tool tip centrally on adrive tooth.

3 Zero the indicator.

4 Turn the differential ring gear withoutturning the drive pinion gear. Record theindicator reading. The allowable backlash is0.203 mm (0.008 in) to 0.305 mm (0.012in) and must not vary more than 0.101 mm(0.004 in) between points measured. Abacklash variation of more than 0.101 mm(0.004 in) between points checked indicatesgear/case runout.

28. Rotate the differential case to make sure it turnsX To correct for a high or low backlash,

freely. proceed as follows.

29. Install the special tool at the 12 o’clockposition.




Differential Shim Size Chart — 406731. To correct for high or low backlash, increase— (Continued)the thickness of one differential bearing shim

and decrease the thickness of the other Dimension ANumbers of Stripes anddifferential bearing shim by the same amount. mm inColor CodeRefer to the following tables when adjusting the

4 — PINK 7.3914- 0.2910-backlash. 7.4041 0.2915

3 — PINK 7.3406- 0.2890-Backlash Change Thickness Change7.3533 0.2895Required Required

2 — PINK 7.2898- 0.2870-mm in mm in7.3025 0.2875

0.025 0.001 0.050 0.0021 — PINK 7.2390- 0.2850-

0.050 0.002 0.050 0.002 7.2517 0.28550.076 0.003 0.101 0.004 5 — GRN 7.1882- 0.2830-

7.2009 0.28350.101 0.004 0.152 0.006

4 — GRN 7.1374- 0.2810-0.127 0.005 0.152 0.0067.1501 0.2815

0.152 0.006 0.203 0.0083 — GRN 7.0866- 0.2790-

0.177 0.007 0.254 0.010 7.0993 0.27950.203 0.008 0.254 0.010 2 — GRN 7.0358- 0.2770-

7.0485 0.27750.228 0.009 0.304 0.012

1 — GRN 6.9850- 0.2750-0.254 0.010 0.355 0.0147.0485 0.2755

0.279 0.011 0.355 0.0145 — WH 6.9342- 0.2730-

0.304 0.012 0.406 0.016 6.9469 0.27350.330 0.013 0.457 0.018 4 — WH 6.8834- 0.2710-0.335 0.014 0.457 0.018 6.8961 0.2715

0.381 0.015 0.508 0.020 3 — WH 6.8326- 0.2690-6.8453 0.2695

2 — WH 6.7818- 0.2670-Differential Shim Size Chart — 4067 — 6.7945 0.2675

Dimension A 1 — WH 6.7310- 0.2650-Numbers of Stripes and6.7437 0.2655mm inColor Code

5 — YEL 6.6802- 0.2630-2 — C-COAL 7.7978- 0.3070-6.6929 0.26357.8105 0.3075

4 — YEL 6.6294- 0.2610-1 — C-COAL 7.7470- 0.3050-6.6421 0.26157.7597 0.3055

3 — YEL 6.5786- 0.2590-5 — BLU 7.6962- 0.3030-6.5913 0.25957.7089 0.3035

2 — YEL 6.5278- 0.2570-4 — BLU 7.6454- 0.3010-6.5405 0.25757.6581 0.3015

1 — YEL 6.4770- 0.2550-3 — BLU 7.5946- 0.2990-6.4897 0.25557.6073 0.2995

5 — ORNG 6.4262- 0.2530-2 — BLU 7.5458- 0.2970-6.4389 0.25357.5565 0.2975

4 — ORNG 6.3754- 0.2510-1 — BLU 7.493- 0.2950-6.3881 0.25157.505 0.2955

3 — ORNG 6.3246- 0.2490-5 — PINK 7.4422- 0.2930-6.3373 0.24957.4549 0.2935




Differential Shim Size Chart — 4067 36. CAUTION: Overspreading may— (Continued)damage the differential housing.

Dimension ANumbers of Stripes and NOTE: Tighten and loosen the differentialmm inColor Code carrier spreader screw to normalize the housing

2 — ORNG 6.2738- 0.2470- spreader adapters prior to taking the final dial6.2865 0.2475 indicator reading.

1 — ORNG 6.2223- 0.2450- Spread the differential housing to the6.2357 0.2455 specification.

2 — RED 6.1722- 0.2430-1 Adjust the special tool to zero.6.1849 0.24352 Tighten the screw until spreading the1 — RED 6.1214- 0.2410-

differential housing to the specification.6.1341 0.2415

3 Remove the special tools.

32. Remove the 4 differential bearing cap bolts.

• Remove the differential assembly.

37. CAUTION: To avoid galling the case,insert shims with a light coating of greasebefore installing the differential assembly. If

33. Measure the thickness of the selected right and not carried out in this order, the aluminumleft bearing shims. housing can be damaged.

Place the differential bearing shims in the34. To establish differential bearing preload,differential housing.increase both the left and right differential

bearing shim thickness by 0.203 mm (0.008 in).

35. Install the special tools.




38. Install the differential assembly. 41. Tighten the 4 differential bearing cap bolts.

1 Position the differential bearing cups on the • Tighten to 105 Nm (77 lb-ft).differential bearings.

2 Lower the differential assembly in placebetween the differential bearing shims.

42. Rotate the differential case to make sure it turnsfreely.

39. NOTE: Hand-tighten the differential bearingcap bolts prior to releasing the carrier spreader.

Install the differential bearing caps and thedifferential bearing cap bolts in their originallocations and positions.

43. Install the special tool at the 12 o’clockposition.

40. Loosen and remove the special tool.




44. Using the special tools, recheck the ring gear 47. CAUTION: The machined surfaces onbacklash. the differential housing and the differential

housing cover must be clean and free of oilbefore applying the new silicone sealant.Cover the inside of the axle before cleaningthe machined surface to preventcontamination.

CAUTION: Install the differentialhousing cover within 15 minutes of applyingthe silicone material.

CAUTION: Allow the sealant to curefor 1 hour before filling the axle withlubricant.

Apply a continuous bead of sealant, of thespecified thickness, to the differential housing45. Apply marking compound and rotate thecover mounting surface.differential assembly 5 complete revolutions.• Use silicone gasket and sealant.

46. Verify an acceptable pattern check. Foradditional information, refer to Diagnosis and 48. Install the differential housing cover.Testing in this section.

49. Fill the axle assembly with the specifiedlubricant.

50. Install the rear axle assembly. For additionalinformation, refer to Rear Axle Assembly inthis section.
