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 205-D044 (D81T-4221-A) or Equivalent Aligning Adapter 205-105 (T76P-4020-A3) Bearing Cup Remover 308-047 (T77F-1102-A) Bearing Preload Tool 205-S337 (T93P-4220-AR) Clutch Housing Alignment Adapter 308-021 (T75L-4201-A) Companion Flange Holding Tool 205-126 (T78P-4851-A) Companion Flange Replacer 205-002 (TOOL-4858-E) (Continued) Blind Hole Puller Set 303-DS005 (D80L-100-A) or Equivalent Bracketry for Dial Indicator 100-D004 (D78P-4201-F) or Equivalent Dial Indicator 100-D005 (D78P-4201-G) or Equivalent Differential Carrier Spreader 205-001 (TOOL-4000-E) or Equivalent Differential Side Bearing Replacer 205-010 (T57L-4221-A2) (Continued) Copyright 2002, Ford Motor Company Last updated: 3/24/2004

205-03-2 Front Drive Axle/Differential Ford 8.8-Inch Ring Gear 205-03-2 Special Tool(s) Special Tool(s) Gauge Block Housing Spreader Adapters 205-110 (T76P-4020-A10) 205-335 (T93P-4000-A) (RH) Gauge Disc Impact Slide Hammer 205-129 (T79P-4020-A18) 100-001 (T50T-100-A) Gauge Tube Inner Axle Shaft Bearing 205-336 (T93P-4020-A) Replacer 205-367 (T96T-3N106-A) Handle Left Master Bearing 205-111 (T76P-4020-A11) 205-338 (T93P-4222-A) Handle Pinion Bearing Cone Replacer 205-153 (T80T-4000-W) 205-005 (T53T-4621-C) Holding Fixture Pinion Bearing Cup Replacer 307-003 (T57L-500-B) 205-024 (T67P-4616-A) Housing Spreader Adapter Pinion Thread Protector 205-368 (T96T-4000-A) (LH) 205-460 (Continued) (Continued)

205-03-3 Front Drive Axle/Differential Ford 8.8-Inch Ring Gear 205-03-3 Special Tool(s) Special Tool(s) Pinion Seal Replacer Axle Shaft Seal Replacer 205-133 (T79P-4676-A) 205-366 (T96T-3B112-A) Right Master Bearing Needle Bearing Replacer 205-339 (T93P-4222-B) 205-362 (T96T-1244-A) Screw Outer Shaft Deflector Replacer 205-109 (T76P-4020-A9) 205-365 (T96T-3A379-A) (Continued) Step Plate 205-D061 (D83T-4205-C2) Universal Bearing Puller 205-055 (T71P-4621-B) Material Item Silicone Gasket and Sealant F7AZ-19554-EA Premium Long Life Grease XG-1-C SAE 75W-90 Premium 4x4 Front Axle Lubricant XY-75W90-TQL Disassembly Specification WSE-M4G323-A4 ESA-M1C75-B WSP-M2C201-A Vacuum Pump Kit 416-D002 (D95L-7559-A) or 1. Remove the front drive axle assembly. For Equivalent additional information, refer to Axle Assembly Front Drive in this section. 2. Remove the vacuum control shield. Remove the three bolts. Remove the shield.

205-03-4 Front Drive Axle/Differential Ford 8.8-Inch Ring Gear 205-03-4 3. Remove the differential housing cover. 6. Remove the E-ring. 1 Remove the drain plug. 2 Drain the fluid. 3 Remove the bolts. 4 Remove the differential housing cover. 7. Disconnect the front axle actuator motor assembly. 1 Fully extend the actuator motor shaft. 2 Plug the vacuum ports. 4. CAUTION: The fixture mounting bolts 3 Pull outward on the front axle actuator must have the minimum specified thread motor assembly. engagement in the carrier. 4 Push the front axle actuator motor assembly Install the special tool. to disconnect the shift lever from the slot in the actuator motor shaft. 5. Unseat the clutch shaft rod boot.

205-03-5 Front Drive Axle/Differential Ford 8.8-Inch Ring Gear 205-03-5 8. 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. 12. Remove the axle clutch gear. 1 Push the axle shaft inward, and remove the snap ring. 2 Remove the axle clutch gear. 10. Secure the axle housing tube in a vise. 13. Remove the steel thrust washer and the tanged thrust washer. 11. Remove the gasket from the sealing groove and flange face.

205-03-6 Front Drive Axle/Differential Ford 8.8-Inch Ring Gear 205-03-6 14. Remove the axle shaft. 18. CAUTION: Be careful not to damage 15. Using the special tools, remove the inner the seal or bearing surfaces. bearing. If necessary, remove the axle shaft dust deflector. 16. Reposition the axle housing tube in the vise, 19. Remove the thrust washer. and remove the axle shaft dust seal. 17. Using the special tools, remove the outer bearing.

205-03-7 Front Drive Axle/Differential Ford 8.8-Inch Ring Gear 205-03-7 20. Remove the axle cluster gear shaft. 23. NOTE: There is enough clearance in the casting to remove the manual shaft retaining pin. If necessary, remove the shift lever and the clutch fork. 1 Drive the manual shaft retaining pin through the clutch fork. 2 Remove the shift lever and the clutch fork. 21. CAUTION: Use a vise with soft jaws. Using the special tool, remove the pilot bearing assembly 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. 24. Remove and discard the O-ring. 22. Lift the shift lever, and remove the coupler shift selector gear.

205-03-8 Front Drive Axle/Differential Ford 8.8-Inch Ring Gear 205-03-8 25. Remove the axle shaft. 28. If necessary, adjust the special tool to provide 1 Remove the snap ring. clearance for the shift lever. 2 Remove the axle shaft. 29. Install the special tools. 26. CAUTION: The housing spreader Position the adapter tip in the spreader adapter bolts must have the minimum adapter hole. specified thread engagement in the carrier. Install the special tools. 27. Position the special tool on the spreader adapters.

205-03-9 Front Drive Axle/Differential Ford 8.8-Inch Ring Gear 205-03-9 30. CAUTION: Overspreading can damage 32. CAUTION: Use wood blocks to avoid the axle housing. axle housing damage. Spread the axle housing to the specification. Remove the differential assembly from the axle 1 Adjust the special tool to zero. housing. 2 Tighten the housing spreader screw to 1 Position the wood blocks. spread the axle housing to the specification. 2 Position and push down on the two pry 3 Remove the Dial Indicator. bars. 3 Remove the differential assembly. 4 Remove the special tool. 31. CAUTION: Mark the differential bearing caps 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. 33. Index-mark the axle universal joint flange to the pinion stem.

205-03-10 Front Drive Axle/Differential Ford 8.8-Inch Ring Gear 205-03-10 34. Install the special tool, and loosen, but do not remove the pinion nut. 35. 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. 38. Discard the drive pinion collapsible spacer. 36. Remove the nut and the flange. 37. 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. 39. CAUTION: Do not damage the carrier housing while removing the pinion seal. Remove the pinion seal and slinger. Pry up on the seal flange. Install gripping pliers, and strike with a hammer to remove the seal. 40. Remove the outer pinion bearing.

205-03-11 Front Drive Axle/Differential Ford 8.8-Inch Ring Gear 205-03-11 41. Using the special tools, remove the inner pinion 44. Using the special tool and a suitable press, bearing cup. remove the pinion bearing. 42. NOTE: The pinion bearing oil baffle aids in 45. NOTE: A drive pinion bearing adjustment shim bearing lubrication. Normally, it is not sits under the pinion bearing. Use a micrometer necessary to remove the baffle. to measure the shim thickness. Record the If necessary, remove the pinion bearing oil measurement for comparison to the shim gauge baffle. reading taken prior to installing the pinion bearing. Remove and measure the drive pinion bearing adjustment shim. 43. Remove the outer pinion bearing cup by tapping alternately on each side to prevent the cup from cocking.

205-03-12 Front Drive Axle/Differential Ford 8.8-Inch Ring Gear 205-03-12 46. Remove the ten bolts and the ring gear. 2. Using the special tool, install the baffle. Use a drift punch to separate the ring gear from the differential case. 3. NOTE: Always install new pinion bearings when installing new pinion bearing cups. 47. Using the special tools, remove the differential Lightly oil the new pinion bearing cups and bearings. pinion bearings with axle lubricant. 4. Using the special tool, install the bearing cups. Assembly 1. CAUTION: Do not omit the pinion bearing oil baffle; bearing failure can result. If removed, position the baffle on the special tool.

205-03-13 Front Drive Axle/Differential Ford 8.8-Inch Ring Gear 205-03-13 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. 7. 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. 6. NOTE: This step duplicates final pinion bearing preload. Tighten the special tool to the specification to simulate bearing preload.

205-03-14 Front Drive Axle/Differential Ford 8.8-Inch Ring Gear 205-03-14 9. NOTE: Use only flat, clean drive pinion 11. Place a new drive pinion collapsible spacer on bearing adjustment shims. the pinion stem. 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. 12. Install the outer pinion bearing. 10. NOTE: You must use the same pinion bearings from the previous steps. 13. Install the slinger. 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.

205-03-15 Front Drive Axle/Differential Ford 8.8-Inch Ring Gear 205-03-15 14. NOTE: Coat the lips of the pinion seal with axle lubricant. 18. CAUTION: Never install the axle universal joint flange with a hammer. Place the pinion seal on the special tool. NOTE: Disregard the scribe marks if installing a new flange. Align the index-marks and position the universal joint flange on the drive pinion. 15. Place the special tool and seal in the pinion seal bore and drive the seal into place. 19. Using the special tool, install the axle universal joint flange. 16. Lightly lubricate the pinion gear splines with axle lubricant. 17. Position the pinion gear in the housing. 20. Apply a small amount of lubricant to the washer side of the new pinion nut, and install the nut.

205-03-16 Front Drive Axle/Differential Ford 8.8-Inch Ring Gear 205-03-16 21. CAUTION: Do not loosen the pinion 22. CAUTION: Use extreme care not to nut to reduce preload under any damage the aluminum differential carrier circumstance. If it is necessary to reduce housing while performing the following preload, install a new drive pinion collapsible procedure steps. spacer and pinion nut. Install the special tool, and tighten the pinion CAUTION: The special tools are nut. Refer to the torque specifications in the marked LH and RH. Install them Specifications portion of this section. accordingly. Install the special tools. 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. 23. Install the differential case with the Master Bearings in the differential carrier.

205-03-17 Front Drive Axle/Differential Ford 8.8-Inch Ring Gear 205-03-17 24. 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. 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. 25. Remove the special tools and the differential case. 28. Install the remaining bolts. 26. Use a fine flat file to remove any burrs or nicks from the ring gear mounting surface.

205-03-18 Front Drive Axle/Differential Ford 8.8-Inch Ring Gear 205-03-18 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. 33. 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. 31. Position the special tools. 34. Remove 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.

205-03-19 Front Drive Axle/Differential Ford 8.8-Inch Ring Gear 205-03-19 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. 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. X Repeat the procedure for the other bearing. 37. Position the differential bearing assembly in the special tool, and tighten the tool. Differential Bearing Shim Selection Chart 39. Select appropriate differential bearing shims. 8.8-inch Aluminum Axle Example Actual Line-A End play without ring gear 0.498 Line-B End play with ring gear (ring -0.245 minus (-) gear side) Line-C Subtract Line-B from Line-A, 0.253 also record on Line C, below

205-03-20 Front Drive Axle/Differential Ford 8.8-Inch Ring Gear 205-03-20 8.8-inch Aluminum Axle Left Differential Bearing Height Right Differential Bearing Height Example Actual Example Actual Master bearing height 0.8695 0.8695 0.8695 0.8695 Line-D Actual bearing height -0.8478 minus (-) -0.8491 minus (-) Line-E Difference 0.0217 0.0204 8.8-inch Aluminum Axle Left Side Right Side Example Actual 8.8-inch Aluminum Axle Example Actual Line-B End play 0.2450 + Line-C End play 0.2530 + Line-E Bearing height +0.0217 Line-E Bearing height +0.0204 TOTAL Lines B and E 0.2667-0.006 TOTAL Lines C and E 0.2734 +0.020 Backlash (subtract) -0.0060 Backlash/preload (add) +0.020 Initial thicknessa 0.2607 Initial thickness 0.2934 Final shim thickness left 0.261 Final shim thickness 0.293 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 Thickness Change Differential Shim Size Chart Numbers of Stripes and Dimension A Color Code mm In. Required Required 2 C-COAL 7.7978-7.8105 0.3070-0.3075 mm In. mm In. 1 C-COAL 7.7470-7.7597 0.3050-0.3055 0.025 0.001 0.050 0.002 5 BLU 7.6962-7.7089 0.3030-0.3035 0.050 0.002 0.050 0.002 4 BLU 7.6454-7.6581 0.3010-0.3015 0.076 0.003 0.101 0.004 3 BLU 7.5946-7.6073 0.2990-0.2995 0.101 0.004 0.152 0.006 2 BLU 7.5458-7.5565 0.2970-0.2975 0.127 0.005 0.152 0.006 1 BLU 7.4930-7.5057 0.2950-0.2955 0.152 0.006 0.203 0.008 5 PINK 7.4422-7.4549 0.2930-0.2935 0.177 0.007 0.254 0.010 4 PINK 7.3914-7.4041 0.2910-0.2915 0.203 0.008 0.254 0.010 3 PINK 7.3406-7.3533 0.2890-0.2895 0.228 0.009 0.304 0.012 2 PINK 7.2898-7.3025 0.2870-0.2875 0.254 0.010 0.355 0.014 1 PINK 7.2390-7.2517 0.2850-0.2855 0.279 0.011 0.355 0.014 5 GRN 7.1882-7.2009 0.2830-0.2835 0.304 0.012 0.406 0.016 4 GRN 7.1374-7.1501 0.2810-0.2815 0.330 0.013 0.457 0.018 3 GRN 7.0866-7.0993 0.2790-0.2795 0.335 0.014 0.457 0.018 2 GRN 7.0358-7.0485 0.2770-0.2775 0.381 0.015 0.508 0.020 1 GRN 6.9850-6.9977 0.2750-0.2755 5 WH 6.9342-6.9469 0.2730-0.2735 4 WH 6.8834-6.8961 0.2710-0.2715 3 WH 6.8326-6.8453 0.2690-0.2695 2 WH 6.7818-6.7945 0.2670-0.2675 1 WH 6.7310-6.7437 0.2650-0.2655 5 YEL 6.6802-6.6929 0.2630-0.2635 4 YEL 6.6294-6.6421 0.2610-0.2615 3 YEL 6.5786-6.5913 0.2590-0.2595 2 YEL 6.5278-6.5405 0.2570-0.2575 1 YEL 6.4770-6.4897 0.2550-0.2555 5 ORNG 6.4262-6.4389 0.2530-0.2535 4 ORNG 6.3754-6.3881 0.2510-0.2515 3 ORNG 6.3246-6.3373 0.2490-0.2495 2 ORNG 6.2738-6.2865 0.2470-0.2475 1 ORNG 6.2223-6.2357 0.2450-0.2455 2 RED 6.1722-6.1849 0.2430-0.2335 1 RED 6.1214-6.1341 0.2410-0.2415

205-03-21 Front Drive Axle/Differential Ford 8.8-Inch Ring Gear 205-03-21 43. NOTE: Make sure the indicator needle is in the spreader adapter hole. Install the special tools. 41. Install the three bolts. 44. CAUTION: Overspreading can damage the axle housing. Spread the axle housing to the specification. Remove the Dial Indicator. 42. CAUTION: Press against the bearing inner cone only. 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.

205-03-22 Front Drive Axle/Differential Ford 8.8-Inch Ring Gear 205-03-22 45. CAUTION: Never attempt to drive the 47. Install the bearing caps in their original differential bearing shim in place. Permanent positions and tighten with the housing still damage to the machined axle housing spread. surfaces can occur. 1 Position the bearing caps. If removed, position the differential bearing 2 Install the bolts. shims. 3 Remove the special tool. 1 Apply a light coating of Premium Long Life Grease to one side of the differential bearing shims to help hold them in place. 2 Position the differential bearing shims. 48. Install the special tool. 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. 2 Lower the differential case assembly in place between the differential bearing shims.

205-03-23 Front Drive Axle/Differential Ford 8.8-Inch Ring Gear 205-03-23 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. 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.

205-03-24 Front Drive Axle/Differential Ford 8.8-Inch Ring Gear 205-03-24 54. 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.

205-03-25 Front Drive Axle/Differential Ford 8.8-Inch Ring Gear 205-03-25 59. 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.

205-03-26 Front Drive Axle/Differential Ford 8.8-Inch Ring Gear 205-03-26 63. 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.

205-03-27 Front Drive Axle/Differential Ford 8.8-Inch Ring Gear 205-03-27 69. 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. 70. Assemble the axle housing tube. 73. NOTE: Do not reuse the old snap ring. Push in on the axle shaft and install a new snap Align the bolt holes and position the axle housing tube. ring. 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.

205-03-28 Front Drive Axle/Differential Ford 8.8-Inch Ring Gear 205-03-28 74. 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.

205-03-29 Front Drive Axle/Differential Ford 8.8-Inch Ring Gear 205-03-29 79. 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. 83. Fill the differential carrier housing, and install the fill plug, using front axle lubricant. 80. Remove the axle assembly from the Holding Be sure to tighten both the drain and fill Fixture and place it on the bench. plugs. 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. 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.