DISASSEMBLY AND ASSEMBLY (Continued)

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Logan Hawkins
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1 Front Drive Axle/Differential Ford 8.8-Inch Ring Gear Measure the ring gear backlash at four places to obtain a consistent reading. 1 Mount the special tools on the indicator base. 2 Position the indicator needle and zero the indicator. 3 Turn the ring gear without turning the pinion gear and record the measurement. 52. Liberally lubricate the axle shaft shift lever, and install a new O-ring. Use Ford Silicone Brake Caliper Grease and Dielectric Compound. 50. NOTE: If the backlash is not within the specifications, correct it by increasing the thickness of one differential bearing shim and decreasing the thickness on the other differential bearing shim by the same amount. To increase the backlash, install a thicker differential bearing shim and a thinner differential bearing shim as shown. 53. Install the axle shaft shift lever. 1 Position the clutch fork. 2 Install the axle shaft shift lever. X Align the manual shaft retaining pin holes. 51. To decrease the backlash, install a thicker differential bearing shim and a thinner differential bearing shim as shown.

2 Front Drive Axle/Differential Ford 8.8-Inch Ring Gear Install the manual shaft retaining pin flush with 57. Insert the axle cluster gear shaft through the the axle shaft shift lever. coupler shift selector gear and engage the splines. 55. Lift the axle shaft shift lever, and position the coupler shift selector gear, tapered end downward, into the clutch fork. 58. Coat the thrust washer with grease, and position it on the axle cluster gear shaft. Use Premium Long Life Grease. 56. Using the special tools, install the pilot bearing assembly into the axle cluster gear shaft.

3 Front Drive Axle/Differential Ford 8.8-Inch Ring Gear CAUTION: The arrow marked 61. Using the special tools, install the axle shaft Inboard on the Needle Bearing Replacer dust seal. tool must point toward the axle housing Make sure the axle shaft dust seal flange is when installing the inner bearing. flush with the axle housing tube. Using the special tools, install the inner bearing. 1 Position the axle housing tube in a vise. 2 Position the inner bearing. 3 Using the special tools, install the inner bearing. 60. CAUTION: The arrow marked Outboard on the Needle Bearing Replacer tool must point toward the axle housing when installing the outer bearing. NOTE: When the tool flange bottoms out on the tube flange, bearing installation is correct. Using the special tools, install the outer bearing. 1 Position the axle housing tube in the vise. 2 Position the outer bearing. 3 Using the special tools, install the outer bearing. 62. If removed, position the axle shaft dust deflector for installation. 1 Position the axle bearing seal plate on the press bed. 2 Position the special tool. 3 Position the axle shaft dust deflector.

4 Front Drive Axle/Differential Ford 8.8-Inch Ring Gear If removed, use a suitable press to press the 67. Install the axle clutch gear. axle shaft dust deflector on the axle shaft. 68. Push in on the axle shaft and install a new snap 64. Insert the axle shaft into the axle housing tube. ring. 65. Lubricate the steel thrust washer. Use Premium Long Life Grease. 66. Install the tanged thrust washer and the steel thrust washer.

5 Front Drive Axle/Differential Ford 8.8-Inch Ring Gear CAUTION: Remove all of the old liquid gasket, and make sure the machined surfaces are free of oil before applying the new silicone rubber. CAUTION: Install the axle housing tube within 15 minutes of applying the silicone, or it will be necessary to remove and reapply new sealant. If possible, allow one hour before filling with lubricant to make sure the silicone has cured. CAUTION: Do not allow any silicone rubber to squeeze inside during assembly. Fill the groove with Silicone Gasket and Sealant. 72. Insert the axle shaft and engage it with the side gear. 73. NOTE: Do not reuse the old snap ring. 70. Assemble the axle housing tube. Push in on the axle shaft and install a new snap Align the bolt holes and position the axle ring. housing tube. Position the axle identification tag. Install the bolts. 71. Examine the axle shaft seal and bearing surface for damage. If necessary, polish the bearing surface with fine crocus cloth.

6 Front Drive Axle/Differential Ford 8.8-Inch Ring Gear Install the clutch shaft rod boot. 77. Seat the clutch shaft rod boot in the slot in the 1 Fully extend the actuator motor shaft and actuator housing. plug the vacuum ports. Remove the plugs from the vacuum ports. 2 Position the front axle actuator motor assembly. 3 Install the clutch shaft rod boot. 75. With the actuator motor shaft fully extended and the vacuum ports plugged, engage the shift lever. 78. NOTE: Install a new vacuum motor if any vacuum leakage is observed. NOTE: With the lever moved outboard, the axle is engaged and the axles will turn opposite of each other. With the lever moved inboard, the axle is disengaged and the axles will turn freely of each other. Verify the front axle actuator motor assembly operation (engage). Using the special tool, apply vacuum to the outer vacuum port to move the shift lever outboard. Rotate one axle shaft to verify engagement. 76. Seat the front axle actuator motor assembly and install the E-ring.

7 Front Drive Axle/Differential Ford 8.8-Inch Ring Gear Verify the front axle actuator motor assembly 82. Install the differential housing cover. operation (disengage). 1 Position the differential housing cover. Using the special tool, apply vacuum to the inner vacuum port to move the shift lever 2 Install the bolts. inboard. Rotate one axle to verify disengagement. 80. Remove the axle assembly from the Holding Fixture and place it on the bench. 81. CAUTION: Remove all of the oil liquid gasket, and make sure the machined surfaces are free of oil before applying the new silicone rubber. CAUTION: Install the differential housing cover within 15 minutes of applying the silicone, or it will be necessary to remove and reapply new sealant. If possible, allow one hour before filling with lubricant to make sure the silicone has cured. Fill the sealing groove on the differential housing cover with Silicone Gasket and Sealant. 83. Fill the differential carrier housing, and install the fill plug, using front axle lubricant. Be sure to tighten both the drain and fill plugs. 84. Install the vacuum control shield. Install the shield. Install the bolts and the torque bolts. 85. Install the front drive axle assembly. For additional information, refer to Axle Assembly Front Drive in this section.

DISASSEMBLY AND ASSEMBLY

205-03-1 Front Drive Axle/Differential Ford 8.8-Inch Ring Gear 205-03-1 DISASSEMBLY AND ASSEMBLY Axle Front Drive Special Tool(s) 2-Jaw Puller 205-D072 (D97L-4221-A) Special Tool(s) Carrier Bearing Replacer