Bronco L6-300 4.9L VIN Y 1-bbl (1983)
Ring Gear: Adjustments
Assembly of Differential Into Housing
Ring Gear & Pinion Backlash
1.
Position differential assembly, with pinion installed, into housing. Ensure master bearings are still assembled in case.
2.
Install dial indicator on carrier housing in same location as when spreading case.
3.
Force ring gear into mesh with pinion, then set dial indicator to ``0'' while maintaining force on differential case.
4.
Force ring gear away from pinion gear and note dial reading. Repeat sequence until same indicator reading is obtained. This measurement
indicates amount of shims needed between differential case and bearings on the ring gear side.
5.
Remove dial indicator and differential case from carrier, then the master bearings from differential case.
6.
Place shims determined in step 4 on ring gear hub of differential case.
7.
Install bearing cone on ring gear side of differential case, then drive bearing into place.
8.
To determine thickness of shims required on hub of drive pinion side of differential case, subtract thickness of shims installed in step 6 from total
differential case endplay as measured in ``Differential Case Assembly'' procedure. To this figure, add .015 inch.
9.
Place shims determined in step 8 on hub of drive pinion side of differential case.
10.
Install bearing cone on hub of drive pinion side of differential case.
11.
Position suitable step plate on ring gear side bearing to protect bearing.
12.
Place bearing on drive pinion side hub and drive it into position.
13.
Install spreader tool and dial indicator as previously described. Do not spread case more than .015 inch.
14.
Assemble differential bearing cups to bearing cones, then install differential assembly into carrier.
15.
Tap differential assembly into position in carrier using a soft-faced hammer, then remove spreader tool from case.
16.
Install bearing caps in proper position, then torque cap screws to 80---90 ft. lbs. on except model 30 axle or 35---50 ft. lbs on model 30 axle.
17.
Measure ring gear and pinion backlash at three equidistant points using a dial indicator. Backlash must measure .004---.009 inch on except model
30 axle or .005---.009 inch on model 30 axle and cannot vary more than .003 inch on except model 30 axle or .002 inch on model 30 axle between
points checked. Backlash may be brought within specifications by switching shims from one side of differential case to the other. Move ring gear
closer to pinion to correct high backlash, or further away from pinion to correct low backlash.
18.
On except model 30 axle having a cover plate without a flat mounting surface, install cover plate, using a new gasket, and torque attaching bolts
alternately and evenly to 30---40 ft. lbs. On model 30 axle, torque cover attaching bolts to 15---25 ft. lbs.
19.
On units having a cover plate with a flat mounting surface, install cover as follows:
a. Clean flat surface of cover plate and carrier mating surface.
b. Apply suitable sealant to cover plate surface, ensuring bead of sealant is laid on inside of cover screw holes.
c. Install two attaching bolts into cover at 2 o'clock and 8 o'clock positions.
d. Position cover on carrier, then install remaining attaching bolts.
e. Torque all attaching bolts alternately and evenly to 30---40 ft. lbs.
