Lincoln Navigator: Front Drive Axle/Differential / Differential Carrier. Removal and Installation

Special Tool(s) / General Equipment

	100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge
	205-001 (TOOL-4000-E) Spreader, Differential Carrier
	205-335 (T93P-4000-A) Spreader, Differential Housing (Plate) TKIT-1993-FLM TKIT-1993-LM TKIT-1996-F/FM
	205-368 (T96T-4000-A) Adapter for Differential Housing Spreader TKIT-1998-LM (NavigatoR) TKIT-1996-F/FM TKIT-1996-FLM2
	307-003 (T57L-500-B) Holding Fixture, Transmission
	307-397 Remover, Transmission Fluid Pump TKIT-2002N-DEW TKIT-2000AP-FLM/LM
	308-021 (T75L-4201-A) Gauge, Clutch Housing
Slide Hammer

Materials

Removal

1. Remove the front axle assembly.
   Refer to: Axle Assembly (205-03 Front Drive Axle/Differential, Removal and Installation).
   

1. Remove the differential cover bolts and differential cover.
   

1. Using the special tool and a slide hammer, remove the axle shaft.
   Use Special Service Tool: 307-397  Remover, Transmission Fluid Pump.
   Use the General Equipment: Slide Hammer

1. Remove and discard the inner and outer circlips.
   

1. Remove the axle tube bolts and the axle tube.
   

1. NOTICE: The fixture mounting bolts must have the minimum of 12.7 mm (0.500 In) of thread engagement in the carrier or damage to the component may occur.

   Using the special tool, mount the axle assembly.
   Use Special Service Tool: 307-003 (T57L-500-B)  Holding Fixture, Transmission.

1. NOTICE: The fixture mounting bolts must have the minimum of 12.7 mm (0.500 In) of thread engagement in the carrier or damage to the component may occur.

   Install the special tools.
   Use Special Service Tool: 205-001 (TOOL-4000-E)  Spreader, Differential Carrier. , 205-335 (T93P-4000-A)  Spreader, Differential Housing (Plate). , 205-368 (T96T-4000-A)  Adapter for Differential Housing Spreader.

1. Install the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge.
   Use Special Service Tool: 100-002 (TOOL-4201-C)  Holding Fixture with Dial Indicator Gauge. , 205-001 (TOOL-4000-E)  Spreader, Differential Carrier. , 308-021 (T75L-4201-A)  Gauge, Clutch Housing.

1. NOTICE: Overspreading may damage the component. Do not spread the differential housing more then 0.762 mm (0.030 in).

   
   Spread the axle housing to the specification.
   
   1. Adjust the Dial Indicator Gauge to zero.
      Use Special Service Tool: 100-002 (TOOL-4201-C)  Holding Fixture with Dial Indicator Gauge. , 308-021 (T75L-4201-A)  Gauge, Clutch Housing.
   2. Tighten the housing spreader screw to spread the axle housing to the specification.
      
   3. Remove the Dial Indicator Gauge with Holding Fixture.
      

1. NOTE: Mark the differential bearing caps Top or Bottom and LH or RH appropriately before removing them. Always install the differential bearing caps in their original positions or damage to the component may occur.

   Remove the differential cap bolts and the differential caps.
   

1. NOTE: The differential bearing cups and shims must be installed in their original locations and positions.

   1. Index-mark the position of the differential bearing cups and shims.
      
   2. Remove the differential carrier, differential bearing cups and the differential side shims.
      

1. If drive pinion bearings or differential bearings are to be replaced, loosen and remove the differential housing spreader.
   

Installation

1. NOTE: If the differential housing spreader was removed, install the same to the differential housing.

   Install the Dial indicator gauge with holding fixture, Clutch housing gauge and Differential Carrier spreader.
   Use Special Service Tool: 100-002 (TOOL-4201-C)  Holding Fixture with Dial Indicator Gauge. , 205-001 (TOOL-4000-E)  Spreader, Differential Carrier. , 308-021 (T75L-4201-A)  Gauge, Clutch Housing.

1. NOTICE: Overspreading may damage the component. Do not spread the differential housing more than 0.762mm (0.030 in).

   NOTE: Tighten and loosen the differential carrier spreader screw to normalize the housing spreader adapters prior to taking the final dial indicator reading.

   
   Spread the differential housing to the specification.
   
   1. Adjust the dial indicator gauge with holding fixture and clutch housing gauge to zero.
      Use Special Service Tool: 100-002 (TOOL-4201-C)  Holding Fixture with Dial Indicator Gauge. , 308-021 (T75L-4201-A)  Gauge, Clutch Housing.
   2. Tighten the screw until spreading the differential housing to the specification.
      
   3. Remove the dial indicator gauge with holding fixture and clutch housing gauge.
      

1. lubricate and install the differential carrier side shims.
   

1. 
   Install the differential carrier.
   
   • Position the differential bearing cups on the differential bearings.
     
   • Lower the differential carrier assembly in place between the differential bearing shims.
     

1. NOTICE: The fixture mounting bolts must have the minimum of 12.7 mm (0.500 In) of thread engagement in the carrier or damage to the component may occur.

   NOTE: Always install the differential bearing caps in their original positions or damage to the component may occur.

   NOTE: Hand-tighten the differential bearing cap bolts prior to releasing the carrier spreader.

   • With the differential housing spread to 0.762 mm (0.030 in) maximum. Install the differential caps and the differential cap bolts.
     
   • Finger tighten the differential bearing cap bolts prior to releasing the carrier spreader.
     Use Special Service Tool: 205-001 (TOOL-4000-E)  Spreader, Differential Carrier. , 205-335 (T93P-4000-A)  Spreader, Differential Housing (Plate). , 205-368 (T96T-4000-A)  Adapter for Differential Housing Spreader.

1. 1. Loosen and Remove the special tools.
      Use Special Service Tool: 205-001 (TOOL-4000-E)  Spreader, Differential Carrier. , 205-335 (T93P-4000-A)  Spreader, Differential Housing (Plate). , 205-368 (T96T-4000-A)  Adapter for Differential Housing Spreader.
   2. Tighten the differential bearing cap bolts.
      Torque: 77 lb.ft (105 Nm)

1. Using the dial indicator, measure the differential ring gear backlash at 4 equally spaced points.
   Use Special Service Tool: 100-002 (TOOL-4201-C)  Holding Fixture with Dial Indicator Gauge.

1. NOTICE: The fixture mounting bolts must have the minimum of 12.7 mm (0.500 In) of thread engagement in the carrier or damage to the component may occur.

   Remove the axle assembly from the special tool.
   Use Special Service Tool: 307-003 (T57L-500-B)  Holding Fixture, Transmission.

1. NOTE: Make sure that the mating surface and the bore is free of corrosion and foreign material, avoid particles getting into the bore. Particles might stick on the vent valve assembly and cause damage to vent valve.

   Clean the mating surface of the axle and the axle tube.
   

1. Apply a new continuous bead of sealant to the differential housing as shown.
   Material: Motorcraft® Ultra Silicone Sealant / TA-29 (WSS-M4G323-A8)

1. Install the axle tube and the axle tube bolts.
   Torque: 54 lb.ft (73 Nm)

1. Install the new inner and outer circlips.
   

1. NOTE: The axle shaft is not fully seated until the circlip is engaged with the differential side gear.

   Install the axle shaft.
   

1. NOTE: Remove all of the silicone gasket and make sure the surfaces are free of oil before applying the new silicone gasket.

   Clean the gasket mating surface of the axle and the differential housing cover.
   

1. NOTE: The differential housing cover must be installed within 15 minutes of application of the silicone, or new sealant must be applied. If possible, allow one hour before filling with lubricant to make sure the silicone sealant has correctly cured.

   Apply a new continuous bead of sealant to the differential housing cover as shown.
   Material: Motorcraft® Ultra Silicone Sealant / TA-29 (WSS-M4G323-A8)

1. Install the differential cover and differential cover bolts.
   Torque: 24 lb.ft (32 Nm)

1. Install the front axle assembly.
   Refer to: Axle Assembly (205-03 Front Drive Axle/Differential, Removal and Installation).