disposablehero27

Alright guys, it seems as if i can't get ahold if the guy to install the gears for me, so i'm going to do this. My dad and very intelligent uncle is going to help, however i'm going to be resposibile, they have bigger problems than making my car better. So what tools do i need, any place i can go for pictures, directions, mic readings and spaces for the shims etc. can you guys help me, if anyone has done it before...

nehila50

This is out of the ford workshop manual, you need special tools to measure pinion depth and a dial indicator to measure backlash, if you cant get the tools to measure pinion depth then reuse the shim on the pinion under the pinion bearing and use gear marking compound to check the pattern.



Differential Ring and Pinion

Special Tool(s) Protector, Drive Pinion Thread
205-460 or equivalent
Installer, Drive Pinion Oil Seal
205-208 (T83T-4676-A)
Installer, Drive Pinion Flange
205-002 (TOOL-4858-E) or equivalent
Dial Indicator Gauge With Bracketry
100-002 (TOOL-4201-C) or equivalent
Remover, Differential Bearing
205-116 (T77F-4220-B1)
Installer, Differential Shim
205-220 (T85L-4067-AH)
Holding Fixture, Drive Pinion Flange
205-126 (T78P-4851-A)
Installer, Drive Pinion Bearing Cup
205-024 (T67P-4616-A)
Adapter For 205-S127
205-105 (T76P-4020-A3)
Adapter For 205-S127
205-111 (T76P-4020-A11)
Adapter For 205-S127
205-109 (T76P-4020-A9)
Adapter For 205-S127
205-129 (T79P-4020-A18)
Adapter For 205-S127
205-110 (T76P-4020-A10)
Adapter For 205-S127
205-130 (T79P-4020-A19)
Installer, Drive Pinion Bearing Cone
205-005 (T53T-4621-C)
2-Jaw Puller
205-D072 (D79L-4221-A1) or equivalent
Step Plate
205-D016 (D80L-630-5) or equivalent
Installer, Differential Side Bearing
205-010 (T57L-4221-A2)
Plate, Bearing Oil Seal
205–090 (T75L-1165–B)

Material Item Specification
Motorcraft SAE 75W-140 High Performance Rear Axle Lubricant
XY-75W140-QL WSL-M2C192-A
Additive Friction Modifier
XL-3 EST-M2C118-A


Item Part Number Description
1 4670 Oil slinger
2 4621 Outer pinion bearing
3 4616 Outer pinion bearing cup
4 4662 Collapsible spacer
5 4628 Inner pinion bearing cup
6 4630 Inner pinion bearing
7 4663 Pinion bearing adjustment shim
8 4209 Drive pinion
9 4209 Ring gear
10 4221 Differential bearings
11 4222 Differential bearing cups
12 4067 Differential bearing shims

Removal

Remove the differential carrier assembly. For additional information, refer to Differential Carrier in this section.
Remove the 10 differential ring gear bolts.

CAUTION: Care should be taken not to damage the differential ring gear bolt hole threads.

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

NOTE: The anti-lock ring cannot be reused once removed. Remove the anti-lock ring only if damaged.

If necessary, remove the anti-lock ring.

Using the special tools, remove the differential bearings.

Index-mark the driveshaft flange and pinion flange for correct alignment during installation.

Remove the 4 driveshaft flange bolts.

CAUTION: The driveshaft centering socket yoke fits tightly on the pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft centering socket yoke from the pinion flange. Pry only in the area shown with a suitable tool to disconnect the driveshaft centering socket yoke from the pinion flange.

Using a suitable tool as shown, disconnect the driveshaft centering socket yoke from the pinion flange.
Using mechanic's wire, position the driveshaft aside.

Using the special tool to hold the pinion flange, remove and discard the pinion nut.

Using the special tool, remove the pinion flange.

Force up on the metal flange of the drive pinion seal. Install gripping pliers and strike with a hammer until the drive pinion seal is removed.

Remove the drive pinion shaft oil slinger and the outer drive pinion bearing.
Install the special tool. Using a soft-faced hammer, drive the pinion assembly out of the axle housing.

Using a brass drift, remove the drive pinion bearing cups by tapping alternately on opposite sides of the drive pinion bearing cups.

Installation

Position the special tool and the inner and outer drive pinion bearing cups in their respective bores.
After placing the inner and outer drive pinion bearing cups in their bores, place the special tool (inner) on the inner drive pinion bearing cup.
Place the special tool (outer) on the outer drive pinion bearing cup.
Install the special tool.

Tighten the special tool to seat the drive pinion bearing cups into their bores.

NOTE: If a feeler gauge can be inserted between a drive pinion bearing cup and the bottom of its bore at any point around the drive pinion bearing cup, the drive pinion bearing cup is not correctly seated.

Make sure the drive pinion bearing cups are correctly seated in their bores.

NOTE: Install new drive pinion bearings without any additional lubricant since the anti-rust oil provides adequate lubricant without upsetting the drive pinion bearing preload settings.

Assemble and position the special tools.


Item Part Number Description
1 205-105 Adapter for 205-S127 (1.612 inch O.D.) (T76P-4020-A3)
2 205-111 Adapter for 205-S127 (T76P-4020-A11)
3 4621 Drive pinion bearing (outer)
4 205-109 Adapter for 205-S127 (T76P-4020-A9)
5 4630 Drive pinion bearing (inner)
6 205-129 Adapter for 105-S127 (1.1884 inch thick) (T79P-4020-A18)
7 205-110 Adapter for 205-S127 (1.7 inch thick) (T76P-4020-A10)

NOTE: This step duplicates final drive pinion bearing preload.

Tighten the special tool.
Tighten to 2.2 Nm (20 lb-in).

NOTE: The special tool must be offset to obtain an accurate reading.

Rotate the special tool several half-turns to make sure of correct seating of the drive pinion bearings and position the special tool.

Install the special tool.
Position the special tool.
Install the differential bearing caps.
Install the 4 differential bearing cap bolts.
Tighten to 105 Nm (77 lb-ft).

NOTE: Drive pinion bearing adjustment shims must be flat and clean.

NOTE: A slight drag should be felt for correct drive pinion bearing adjustment shim selection. Do not attempt to force the drive pinion bearing adjustment shim between the gauge block and the gauge tube. This will minimize selection of a drive pinion bearing adjustment shim thicker than required, which results in a deep tooth contact in final assembly of integral axle assemblies.

Use a drive pinion bearing adjustment shim as a gauge for drive pinion bearing adjustment shim selection.
After the correct drive pinion bearing adjustment shim thickness has been determined, remove all of the special tools.

Using the special tool and a shop press, drive the inner drive pinion bearing and the selected drive pinion bearing adjustment shim until they are firmly seated on the pinion shaft.

Install a new drive pinion collapsible spacer on the pinion shaft against the pinion shaft shoulder.

Install the drive pinion assembly into the axle housing.

Install the outer drive pinion bearing and the drive pinion shaft oil slinger.
Using the special tools, install the drive pinion seal.

Using the special tools, install the drive pinion flange.

CAUTION: Do not, under any circumstance, loosen the drive pinion nut to reduce pinion bearing preload. If it is necessary to reduce the preload, install a new drive pinion collapsible spacer and drive pinion nut.

CAUTION: Remove the special tool while taking rotational pinion bearing preload checks with the Nm (lb-in) torque wrench.

Use the special tool to hold the pinion flange while tightening the pinion nut.
Rotate the pinion occasionally to make sure the differential pinion bearings are seating correctly. Take frequent differential pinion bearing preload checks by rotating the differential pinion with a Nm (lb-in) torque wrench. Tighten the pinion nut in small increments to avoid excessive pinion bearing preload. Tighten the pinion nut until the drive pinion bearing preload is in specification.

Using the special tool, install the new differential bearings.

NOTE: Apply stud and bearing mount to the differential ring gear bolts.

Install the differential ring gear bolts.
Tighten to 105 Nm (77 lb-ft).

Position the differential carrier assembly and the new differential bearing cups in the differential housing.

Install a differential bearing shim of the shown dimension on the left side.

CAUTION: Always install the bearing caps in their original locations and positions.

NOTE: Apply pressure toward the LH side to make sure the left differential bearing cup seats correctly.

Install the LH bearing cap and loosely install the bolts.

Install progressively larger differential bearing shims on the RH side until the largest shim is installed by hand.

Install the right side bearing cap and bolts. Tighten the LH and RH bearing cap bolts.
Tighten to 105 Nm (77 lb-ft).
Rotate the differential carrier several times to verify the differential bearings have seated correctly.

Install the special tools and measure the ring gear backlash.
If the backlash is within specification, proceed to Step 27.
If a zero backlash condition occurs, proceed to Step 25.
If the backlash is not within specification, proceed to Step 26.

If a zero backlash condition occurs, add 0.50 mm (0.020 in) to the RH side shim and subtract 0.50 mm (0.020 in) from the LH side shim to allow a backlash indication. Go back to Step 24.
To correct for high or low backlash, increase the thickness of one differential bearing shim and decrease the thickness of the other differential bearing shim by the same amount. Refer to the following tables when adjusting the backlash. When the backlash is within specification, proceed to Step 27.

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



Differential Shim Size Chart 4067 Stripes and Color Code Dimension A
mm Inch
2 — C-COAL 7.7978-7.8105 0.3070-0.3075
1 — C-COAL 7.7470-7.7597 0.3050-0.3055
5 — BLU 7.6962-7.7089 0.3030-0.3035
4 — BLU 7.6454-7.6581 0.3010-0.3015
3 — BLU 7.5946-7.6073 0.2990-0.2995
2 — BLU 7.5458-7.5565 0.2970-0.2975
5 — PINK 7.4422-7.4549 0.2930-0.2935
4 — PINK 7.3914-7.4041 0.2910-0.2915
3 — PINK 7.3406-7.3533 0.2890-0.2895
2 — PINK 7.2898-7.3025 0.2870-0.2875
1 — PINK 7.2390-7.2517 0.2850-0.2855
5 — GRN 7.1882-7.2009 0.2830-0.2835
4 — GRN 7.1374-7.1501 0.2810-0.2815
3 — GRN 7.0866-7.0993 0.2790-0.2795
2 — GRN 7.0358-7.0485 0.2770-0.2775
1 — GRN 6.9850-7.0485 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 0.2430-0.2435
1 — RED 6.1214-6.1341 0.2410-0.2415


Remove the bearing cap bolts and bearing caps.
To establish differential bearing preload, increase both LH and RH differential bearing shim size by the thickness shown.

Using the special tool, fully seat the differential bearing shims. Make sure the assembly rotates freely.

Install the bearing caps and bolts.
Tighten to 105 Nm (77 lb-ft).

Using the special tools, recheck the ring gear backlash.
Apply marking compound and rotate the differential assembly 5 complete revolutions.
Check for an acceptable pattern.
Install the axle shafts. For additional information, refer to Axle Shaft in this section.
CAUTION: Make sure the machined surfaces on both the axle housing and the differential housing cover are clean and free of oil before applying the new silicone sealant. The inside of the axle must be covered when cleaning the machined surface to prevent contamination.

Clean the gasket mating surface of the axle and the differential housing cover.
Apply a new, continuous bead of sealant to the differential housing cover.

CAUTION: For Traction-Lok® axles, first fill the axle with 118 ml (4 ounces) of friction modifier.

NOTE: Service refill capacities are determined by filling the axle with the specified lubricant to the specified level below the bottom of the filler hole.

Fill the axle to the level shown with axle lubricant and install the filler plug.
Tighten to 30 Nm (22 lb-ft).

Position the driveshaft and align the index marks on the pinion flange.

CAUTION: The driveshaft centering socket yoke fits tightly on the pinion flange pilot. To make sure that the driveshaft centering socket yoke seats squarely on the pinion flange, tighten the driveshaft flange bolts evenly in a cross pattern.

Install the driveshaft flange bolts.
Tighten to 103 Nm (76 lb-ft).

WhiteFoxGT

Wow, where to begin.

I hope you have more than a basic set of hand tools at your disposal. Also, your going to need an impact and compressor with enough *** to back that gun. Also, a 1 1/16th socket for the pinion nut.

Heres my super short version of a how-to. Yank the tires, brake calipers, rotors. CAREFULLY remove the ABS sensors. Mark and remove the driveshaft. Remove the diff cover and 8mm bolt holding the pin in the diff. Slide pin out, remove C-clips, slide axles out. When that big pin is out, DO NOT rotate the rear by the axles, because you can spin the spiders out. (big PIA if you do) Remove the 4 19mm cap bolts and caps, mark how they went and which side. Use a pry bar and wiggle the Diff out. Remove the big pinion nut and using a hammer carefully tap the flange off. Once that is out of the way the pinion will most likely be stuck in the housing. I use an air hammer but sometimes a BFH is needed.

Once you get all the old crap out, you need the shim off the back of the old pinion. So CAREFULLY cut/press/bang (however you plan on doin it) that pinion bearing off. An easy way that will destroy your old pinion is to just bang the threaded end on the anvil end of the vice and the bearing will slide off slowly. Anyway, re-use the old shim, press on a new pinion bearing. You should replace all bearings and races. This is where I am goin to stop. If you dont think you can do this then please dont attempt it (you sound pretty clueless if your asking us how to do this anyway)

I honestly think gear swap arent something just anyone can do (do right!) Please have someone who knows what they are doin work on it, you will thank me later. I cant even count the amount of rears I have rebuilt anymore...

disposablehero27

oh yeah man, my uncle has built cars from scratch, frame and all..but he hates fords number one haha, and he was in his 20's then. so i'm just trying to get all the info and tools and everything ready with some insight and pretty much i'll put in the wrench work, he'll put in the brain work and the tedious tough/percise stuff. preciate the info.

devongarver

good pics on american muscle in the tech section, there is a basic how to for the install. But really, I'd look further for a shop to do it. I had to drive over an hour to get mine, but they make zero noise, and i know they were done right.

disposablehero27

yeah man, i can't find ANYONE. and the one guy that done the 3.73's has disappeared. and i drove 1hr and a half for the install. i know its no easy thing to do.

WhiteFoxGT

Its not so much the "work" thats tough, its the skill.. If that makes any sense. You're supposed to set the pinion depth then set the pre-load to like 25 in-lbs, I can do that by feel with an impact now.. The shims on the side of the carrier are re-usable, but you have to install them very carefully because they will snap. Its just little tedious things like that I would want you to have a shop do. But anyway, good luck

disposablehero27

Hey guys i appreciate it... he was on vacation, and finally called. $250 to install! phew, i was getting worried.

SVTeeshirt

hey white fox, do my gears lol my dad did his in his dirt track car but hes not trying to do mine for me .

WhiteFoxGT

150$ and you supply the parts...