Lincoln Navigator: Rear Drive Axle/Differential - Vehicles With: Ford 9.75 Inch Ring Gear / Differential Carrier. Removal and Installation

Special Tool(s) / General Equipment

	205-220 Installer, Differential Shim TKIT-1985-FH
	307-003 (T57L-500-B) Holding Fixture, Transmission

Materials

Removal

1. Remove the rear drive axle assembly
   Refer to: Axle Assembly (205-02 Rear Drive Axle/Differential - Vehicles With: Ford 9.75 Inch Ring Gear, Removal and Installation).
   

1. Remove and discard the torque arm bolts and remove the torque arm from the rear axle housing.
   

1. Remove and discard the torque arm locating sleeves.
   

1. • Remove the differential housingcover bolts.
     
   • Remove the differential housing cover.
     

1. Using the Transmission Holding Fixture, mount the differential housing to a work bench.
   Use Special Service Tool: 307-003 (T57L-500-B)  Holding Fixture, Transmission.

1. NOTE: The differential bearing caps and differential bearing cap bolts need to be installed in the same location as removed.

   Remove the differential bearing cap bolts and differential bearing caps.
   

1. Remove the differential carrier, differential carrier bearing cups and the differential shims.
   

Installation

1. NOTE: Have the selected shims available at this time. It will be required to hold the differential carrier and the differential carrier bearing cups in until shims are installed.

   Install the differential carrier and the differential carrier bearing cups.
   

1. NOTE: Differential bearing shims are to be installed with the chamfer facing outboard.

   • Install the RH selected ring gear back lash shim.
     
   • Position the differential to the RH of the differential housing.
     

   • NOTE: The differential bearing cap bolts should only be finger tight at this time.

     Install the RH differential bearing cap and the differential bearing cap bolts.
     

1. Using the special tool and a soft face brass mallet, install the LH selected ring gear back lash shim.
   Install Special Service Tool: 205-220  Installer, Differential Shim.

1. NOTE: The differential bearing cap bolts should only be finger tight at this time.

   Install the LH differential bearing cap and the differential bearing cap bolts.
   

1. Tighten the differential bearing cap bolts.
   Torque: 83 lb.ft (112 Nm)

1. Check the ring gear backlash.
   Refer to: Ring Gear Backlash Adjustment (205-02 Rear Drive Axle/Differential - Vehicles With: Ford 9.75 Inch Ring Gear, General Procedures).
   

1. Clean the differential carrier gasket surface.
   Refer to: RTV Sealing Surface Cleaning and Preparation (303-00 Engine System - General Information, General Procedures).
   

1. Clean the differential housing.
   

1. NOTE: The compound sets in 20 minutes. Install the differential carrier assembly before the compound sets or remove and re-apply.

   Apply a 2-3mm bead of silicone sealant gasket material onto the carrier housing mounting flange.
   Material: Motorcraft® Ultra Silicone Sealant / TA-29 (WSS-M4G323-A8)

1. • Install the differential housing cover and bolts.
     Torque: 33 lb.ft (45 Nm)

1. NOTE: Make sure that new components are installed.

   Install the new torque arm locating sleeves.
   

1. NOTE: The torque arm bolts must be tightened in the sequence below. If there is clearance in-between the head of the bolt and the torque arm, remove the torque arm bolts and reinstall following the sequence below.

   Position the torque arm to the rear axle housing and install the new torque arm bolts hand tight.
   Torque:
      Tighten item 1 to :   20 lb.ft (27 Nm)
      Tighten item 2 to :   150 lb.ft (203 Nm)
      Tighten item 1 to :   150 lb.ft (203 Nm)

1. Install the rear drive axle assembly
   Refer to: Axle Assembly (205-02 Rear Drive Axle/Differential - Vehicles With: Ford 9.75 Inch Ring Gear, Removal and Installation).