1999 F-150/250 Workshop Manual

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1 Page 1 of 30 SECTION : Front Drive Axle/Differential Ford 8.8-Inch Ring Gear 1999 F-150/250 Workshop Manual DISASSEMBLY AND ASSEMBLY Procedure revision date: 01/08/2003 Axle Front Drive Special Tool(s) 2-Jaw Puller 205-D072 (D97L-4221-A) Aligning Adapter (T76P-4020-A3) Bearing Cup Remover (T77F-1102-A) Bearing Preload Tool 205-S337 (T93P-4220-AR) Blind Hole Puller Set 303-DS005 (D80L-100-A) or Equivalent Bracketry for Dial Indicator 100-D004 (D78P-4201-F) or Equivalent Carrier Bearing Replacer 205-D044 (D81T-4221-A) or Equivalent Clutch Housing Alignment Adapter (T75L-4201-A) Companion Flange Holding Tool (T78P-4851-A) Companion Flange Replacer (TOOL-4858-E) Dial Indicator 100-D005 (D78P-4201-G) or Equivalent Differential Carrier Spreader (TOOL-4000-E) or Equivalent

2 Page 2 of 30 Differential Side Bearing Replacer (T57L-4221-A2) Gauge Block (T76P-4020-A10) Gauge Disc (T79P-4020-A18) Gauge Tube (T93P-4020-A) Handle (T76P-4020-A11) Handle (T80T-4000-W) Holding Fixture (T57L-500-B) Housing Spreader Adapter (T96T-4000-A) (LH) Housing Spreader Adapters (T93P-4000-A) (RH) Impact Slide Hammer (T50T-100-A) Inner Axle Shaft Bearing Replacer (T96T-3N106-A) Left Master Bearing (T93P-4222-A)

3 Page 3 of 30 Pinion Bearing Cone Replacer (T53T-4621-C) Pinion Bearing Cup Replacer (T67P-4616-A) Pinion Thread Protector Pinion Seal Replacer (T79P-4676-A) Right Master Bearing (T93P-4222-B) Screw (T76P-4020-A9) Step Plate 205-D061 (D83T-4205-C2) Universal Bearing Puller (T71P-4621-B) Vacuum Pump Kit 416-D002 (D95L-7559-A) or Equivalent Disassembly 1. Remove the front drive axle assembly. For additional information, refer to Axle Assembly Front Drive in this section. 2. Remove the vacuum control shield. Remove the three bolts. Remove the shield. 3. Remove the differential housing cover (3N136). 1. Remove the drain plug (390943). 2. Drain the fluid. 3. Remove the bolts. 4. Remove the differential housing cover.

4 Page 4 of CAUTION: The fixture mounting bolts must have the minimum specified thread engagement in the carrier. Install the special tool. 5. Unseat the clutch shaft rod boot (7W082). 6. Remove the E-ring. 7. Disconnect the front axle actuator motor assembly (7G360). 1. Fully extend the actuator motor shaft. 2. Plug the vacuum ports. 3. Pull outward on the front axle actuator motor assembly. 4. Push the front axle actuator motor assembly to disconnect the shift lever (7K336) from the slot in the actuator motor shaft.

5 Page 5 of Remove the clutch shaft rod boot, and the front axle actuator motor assembly. 1. Remove the clutch shaft rod boot. 2. Remove the front axle actuator motor assembly. 9. Remove the axle housing tube (3B210). 10. Remove the thrust washer (3N126). 11. Remove the axle cluster gear shaft (7L253). 12. CAUTION: Use a vise with soft jaws. Using the special tool, remove the pilot bearing assembly (3N106) from the axle cluster gear shaft. 1. Position the axle cluster gear shaft in the vise. 2. Using the special tool, remove the pilot bearing assembly.

6 Page 6 of Lift the shift lever, and remove the coupler shift selector gear (7R262). 14. NOTE: There is enough clearance in the casting to remove the manual shaft retaining pin (7G100). If necessary, remove the shift lever and the clutch fork (3N139). 1. Drive the manual shaft retaining pin through the clutch fork. 2. Remove the shift lever and the clutch fork. 15. Remove and discard the O-ring. 16. Remove the axle shaft (3A381). 1. Remove the snap ring. 2. Remove the axle shaft.

Page 7 of 30 17. CAUTION: The housing spreader adapter bolts must have the minimum specified thread engagement in the carrier. Install the special tools. 18.

7 Page 7 of CAUTION: The housing spreader adapter bolts must have the minimum specified thread engagement in the carrier. Install the special tools. 18. Position the special tool on the spreader adapters. 19. If necessary, adjust the special tool to provide clearance for the shift lever. 20. Install the special tools. Position the adapter tip in the spreader adapter hole. 21. CAUTION: Overspreading can damage the axle housing. Spread the axle housing to the specification. 1. Adjust the special tool to zero. 2. Tighten the housing spreader screw to spread the axle housing to the specification. 3. Remove the Dial Indicator.

Always install the bearing caps in their original place and position. Mark and remove the differential bearing caps. 1.

Remove the differential assembly from the axle housing. 1. Position the wood blocks. 2.

8 Page 8 of CAUTION: Mark the differential bearing caps (4224) Top or Bottom and LH or RH appropriately before removing them. Always install the bearing caps in their original place and position. Mark and remove the differential bearing caps. 1. Remove the bolts. 2. Remove the differential bearing caps. 23. CAUTION: Use wood blocks to avoid axle housing damage. Remove the differential assembly from the axle housing. 1. Position the wood blocks. 2. Position and push down on the two pry bars. 3. Remove the differential assembly. 4. Remove the special tool. 24. Index-mark the axle universal joint flange (4858) to the pinion stem. 25. Install the special tool, and loosen, but do not remove the pinion nut.

9 Page 9 of With the pinion nut still engaged by a few threads, use the special tool to separate the axle universal joint flange from the pinion gear (3N175). 27. Remove the nut and the flange. 28. Using the special tool and a soft hammer, remove the pinion gear. 1. Install the special tool. 2. Hold the pinion gear inside the carrier housing. 3. Using a soft face hammer, remove the pinion gear from the carrier housing. 29. Discard the drive pinion collapsible spacer (4662). 30. CAUTION: Do not damage the carrier housing while removing the pinion seal. Remove the pinion seal (3N134) and slinger (386989). Pry up on the seal flange. Install gripping pliers, and strike with a hammer to remove the seal.

10 Page 10 of Remove the outer pinion bearing (4621). 32. Using the special tools, remove the inner pinion bearing cup (4628). 33. NOTE: The pinion bearing oil baffle (4631) aids in bearing lubrication. Normally, it is not necessary to remove the baffle. If necessary, remove the pinion bearing oil baffle. 34. Remove the outer pinion bearing cup (4616) by tapping alternately on each side to prevent the cup from cocking. 35. Using the special tool and a suitable press, remove the pinion bearing (4630).

Page 11 of 30 36. NOTE: A drive pinion bearing adjustment shim (4663) sits under the pinion bearing. Use a micrometer to measure the shim thickness.

11 Page 11 of NOTE: A drive pinion bearing adjustment shim (4663) sits under the pinion bearing. Use a micrometer to measure the shim thickness. Record the measurement for comparison to the shim gauge reading taken prior to installing the pinion bearing. Remove and measure the drive pinion bearing adjustment shim. 37. Remove the ten bolts and the ring gear (3A397). Use a drift punch to separate the ring gear from the differential case (4205). 38. Using the special tools, remove the differential bearings (4221). Assembly 1. CAUTION: Do not omit the pinion bearing oil baffle; bearing failure can result. If removed, position the baffle on the special tool. 2. Using the special tool, install the baffle.

12 Page 12 of NOTE: Always install new pinion bearings when installing new pinion bearing cups. Lightly oil the new pinion bearing cups and pinion bearings with Motorcraft SAE75W-90 Premium 4x4 Front Axle Lubricant XY-75W90-TQL or equivalent meeting Ford specification WSP-M2C201-A. 4. Using the special tool, install the bearing cups. 5. NOTE: You must use the pinion bearings assembled in this procedure step at final assembly. Assemble and position the special tools and the pinion bearings in the carrier housing. 1. Position the Screw. 2. Position the Aligning Adapter. 3. Position the pinion bearing. 4. Position the Gauge Disc. 5. Position the Gauge Block. 6. Position the pinion bearing. 7. Thread on the Handle. 6. NOTE: This step duplicates final pinion bearing preload. Tighten the special tool to the specification to simulate bearing preload.

13 Page 13 of NOTE: Offset the Gauge Block to obtain an accurate reading. Rotate the Gauge Block several half-turns to make sure the pinion bearings seat correctly, and position the Gauge Block. 8. Install the special tool. 1. Position the special tool. 2. Install the differential bearing caps. 3. Install the bolts. 9. NOTE: Use only flat, clean drive pinion bearing adjustment shims. NOTE: Selection of a shim that is too thick results in a deep tooth contact at final assembly of integral axle assemblies. Do not attempt to force the shim between the Gauge Block and the Gauge Tube. A slight drag indicates correct shim selection. Use a drive pinion bearing adjustment shim as a gauge for shim selection. Check the adjustment shim thickness between the Gauge Block and the Gauge Tube. After determining the correct shim thickness, remove the special tools. 10. NOTE: You must use the same pinion bearings from the previous steps. Install the pinion bearing. Place the drive pinion bearing adjustment shim on the pinion gear. Using a suitable press and the special tool, press the pinion bearing until it is firmly seated on the pinion gear.

14 Page 14 of Place a new drive pinion collapsible spacer on the pinion stem. 12. Install the outer pinion bearing. 13. Install the slinger. 14. NOTE: Coat the lips of the pinion seal with Motorcraft SAE 75W-90 Premium 4x4 Front Axle Lubricant XY-75W90-TQL or equivalent meeting Ford specification WSP-M2C201-A. Place the pinion seal on the special tool. 15. Place the special tool and seal in the pinion seal bore and drive the seal into place.

15 Page 15 of Lightly lubricate the pinion gear splines with Motorcraft SAE 75W-90 Premium 4x4 Front Axle Lubricant XY-75W90-TQL or equivalent meeting Ford specification WSP-M2C201-A. 17. Position the pinion gear in the housing. 18. CAUTION: Never install the axle universal joint flange with a hammer. NOTE: Disregard the scribe marks if installing a new flange. Align the index-marks and position the universal joint flange on the drive pinion. 19. Using the special tool, install the axle universal joint flange. 20. Apply a small amount of lubricant to the washer side of the new pinion nut, and install the nut.

16 Page 16 of CAUTION: Do not loosen the pinion nut to reduce preload under any circumstance. If it is necessary to reduce preload, install a new drive pinion collapsible spacer and pinion nut. Install the special tool, and tighten the pinion nut. Refer to the torque specifications in the Specifications portion of this section. Rotate the pinion gear occasionally to make sure the pinion bearings are seating correctly. Take frequent pinion bearing torque preload readings by rotating the pinion gear with an Nm (inch/pound) torque wrench. 22. CAUTION: Use extreme care not to damage the aluminum differential carrier housing while performing the following procedure steps. CAUTION: The special tools are marked LH and RH. Install them accordingly. Install the special tools. 23. Install the differential case with the Master Bearings in the differential carrier.

17 Page 17 of NOTE: Repeat this step until you obtain a consistent reading. Measure the total end play. 1. Position the special tools. 2. Position the indicator tip on the machined surface and adjust it to measure full travel. 3. Push the differential case left and right (as far as possible). 4. Measure the total end play and record the reading on the Differential Bearing Shim Selection Procedure Worksheet, Line A, in this procedure. 25. Remove the special tools and the differential case. 26. Use a fine flat file to remove any burrs or nicks from the ring gear mounting surface. 27. Install the ring gear. 1. Position three bolts to align the holes in the ring gear and the differential case. 2. Using a suitable press, install the ring gear.

Page 18 of 30 28. Install the remaining bolts. 29. Remove three adjacent bolts. 30. CAUTION: Position the three empty bolt holes downward.

18 Page 18 of Install the remaining bolts. 29. Remove three adjacent bolts. 30. CAUTION: Position the three empty bolt holes downward. Position the differential case with the special tools into the differential carrier housing. 31. Position the special tools. 32. Push and rock the ring gear into mesh with the pinion gear (zero backlash) and adjust the special tool to zero.

19 Page 19 of Move the ring gear away from the pinion gear as far as possible. Record the reading on the Differential Bearing Shim Selection Procedure Worksheet, Line B, in this procedure. 34. Remove the special tools. 35. Remove the differential case and the special tools. 36. NOTE: Measure both of the differential bearing stand heights prior to installing them on the differential case. NOTE: Mark the left and right differential bearings before measuring them. Clamp the special tool base in a soft jawed vise with the bearing mounting surface above the surface of the vise.

20 Page 20 of Position the differential bearing assembly in the special tool, and tighten the tool. 38. Measure the differential bearing stand height. 1. Invert the special tool and bearing assembly in the vise. 2. Use a depth micrometer to measure and record the differential bearing stand height. Repeat the procedure for the other bearing. 39. Select appropriate differential bearing shims. Differential Bearing Shim Selection Chart 8.8-inch Aluminum Axle Example Actual Line-A End play without ring gear Line-B End play with ring gear (ring gear side) minus (-) Line-C Subtract Line-B from Line-A, also record on Line C, below Left Differential Bearing Height Right Differential Bearing Height 8.8-inch Aluminum Axle Example Actual Example Actual Master bearing height Line-D Actual bearing height minus (-) minus (-) Line-E Difference inch Aluminum Axle Line-B End play Left Side Example Actual 8.8-inch Aluminum Axle Line-C End play Right Side Example Actual Line-E Bearing height Line-E Bearing height TOTAL Lines B and E TOTAL Lines C and E Backlash (subtract) Backlash/preload (add) Initial thickness a Initial thickness Final shim thickness left Final shim thickness right a Round off initial thickness to the nearest shim thickness as in example for final shim thickness. 40. Select the appropriate shim by the thickness or the stripe color. Backlash Change Required Thickness Change Required mm In. mm In

21 Page 21 of Differential Shim Size Chart Dimension A Numbers of Stripes and Color Code mm In. 2 C-COAL C-COAL 5 BLU 4 BLU 3 BLU 2 BLU 1 BLU 5 PINK 4 PINK 3 PINK 2 PINK 1 PINK 5 GRN 4 GRN 3 GRN 2 GRN 1 GRN 5 WH 4 WH 3 WH 2 WH 1 WH 5 YEL 4 YEL 3 YEL 2 YEL 1 YEL 5 ORNG 4 ORNG 3 ORNG 2 ORNG

22 Page 22 of 30 1 ORNG 2 RED 1 RED Install the three bolts. 42. CAUTION: Press against the bearing inner cone only.

23 Page 23 of 30 Using a suitable press and the special tool, install the differential bearings. 1. Position the appropriate differential bearing (RH or LH). 2. Using a suitable press and the special tool, install the differential bearing. Repeat the procedure for the other differential bearing. 43. NOTE: Make sure the indicator needle is in the spreader adapter hole. Install the special tools. 44. CAUTION: Overspreading can damage the axle housing. Spread the axle housing to the specification. Remove the Dial Indicator. 45. CAUTION: Never attempt to drive the differential bearing shim in place. Permanent damage to the machined axle housing surfaces can occur. If removed, position the differential bearing shims. 1. Apply a light coating of Premium Long Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B to one side of the differential bearing shims to help hold them in place. 2. Position the differential bearing shims. 46. NOTE: Push the differential case downward to fully seat the differential bearing cups in the axle housing. Position the differential case assembly. 1. Position the differential bearing cups on the differential bearings.

Page 24 of 30 2. Lower the differential case assembly in place between the differential bearing shims. 47.

Install the special tool. 49. Measure the ring gear backlash at four places to obtain a consistent reading. 1. Mount the special tools on the indicator base. 2.

24 Page 24 of Lower the differential case assembly in place between the differential bearing shims. 47. Install the bearing caps in their original positions and tighten with the housing still spread. 1. Position the bearing caps. 2. Install the bolts. 3. Remove the special tool. 48. Install the special tool. 49. 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. 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.

25 Page 25 of To decrease the backlash, install a thicker differential bearing shim and a thinner differential bearing shim as shown. 52. Liberally lubricate the axle shaft shift lever, and install a new O-ring. Use Ford Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or equivalent meeting Ford specification ESE- M1C171-A. 53. Install the axle shaft shift lever. 1. Position the clutch fork. 2. Install the axle shaft shift lever. Align the manual shaft retaining pin holes. 54. Install the manual shaft retaining pin flush with the axle shaft shift lever. 55. Lift the axle shaft shift lever, and position the coupler shift selector gear, tapered end downward, into the clutch fork.

26 Page 26 of Using the special tools, install the pilot bearing assembly into the axle cluster gear shaft. 57. Insert the axle cluster gear shaft through the coupler shift selector gear and engage the splines. 58. Coat the thrust washer with grease, and position it on the axle cluster gear shaft. Use Premium Long Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 59. 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 F7AZ EA or equivalent meeting Ford specification WSE-M4G323-A4.

27 Page 27 of Assemble the axle housing tube. Align the bolt holes and position the axle housing tube. Position the axle identification tag. Install the bolts. 61. Examine the axle shaft seal and bearing surface for damage. If necessary, polish the bearing surface with fine crocus cloth. 62. Insert the axle shaft and engage it with the side gear. 63. NOTE: Do not reuse the old snap ring. Push in on the axle shaft and install a new snap ring.

28 Page 28 of Install the clutch shaft rod boot. 1. Fully extend the actuator motor shaft and plug the vacuum ports. 2. Position the front axle actuator motor assembly. 3. Install the clutch shaft rod boot. 65. With the actuator motor shaft fully extended and the vacuum ports plugged, engage the shift lever. 66. Seat the front axle actuator motor assembly and install the E-ring. 67. Seat the clutch shaft rod boot in the slot in the actuator housing. Remove the plugs from the vacuum ports. 68. 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.

29 Page 29 of Verify the front axle actuator motor assembly operation (disengage). Using the special tool, apply vacuum to the inner vacuum port to move the shift lever inboard. Rotate one axle to verify disengagement. 70. Remove the axle assembly from the Holding Fixture and place it on the bench. 71. 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 F7AZ EA or equivalent meeting Ford specification WSE- M4G323-A Install the differential housing cover. 1. Position the differential housing cover. 2. Install the bolts. 73. Fill the differential carrier housing, and install the fill plug. Use Motorcraft SAE 75W-90 Premium 4x4 Front Axle Lubricant XY-75W90-TQL or equivalent meeting Ford specification WSP-M2C201-A. Be sure to tighten both the drain and fill plugs.

30 Page 30 of Install the vacuum control shield. Install the shield. Install the bolts and the torque bolts. 75. 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