(Gears Gone Wild - continued)

Install the driveshaft flange and the new pinion nut (supplied
with FMS gearsets.) The nut requires about 150 lb-ft of
torque to crush the sleeve. You want to achieve about
25 in-lb. of frictional resistance when turning the pinion.
Begin by torquing the nut to 120 lb-ft. Then turn the
pinion and check resistance. Apply torque in 10 lb-ft
increments until the correct resistance is achieved.
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Getting the torque on the nut is tough because the pinion
will spin. Here we've put a bolt in the driveshaft flange
and are using a wrench on the bolt to counter the breaker
bar. The foot ads in stability. Whatever it takes, get
that crush sleeve crushed. |

The new 3.73:1 gear assembly is set into the carrier.
Be sure the races are on the bearings before setting into
place.
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Install the bearing caps to their respective sides based
on your earlier markings and torque to 75-85 lb-ft. |

Using a dial indicator and magnetic base John checks for
proper backlash. The dial indicator touches a tooth on
the ring gear. Rock the gear gently until it just contacts
the pinion gear tooth. This is the "backlash",
or space between the two gears. Ford calls for .0005-.0010".
If you are out of spec shims are required against the
carrier bearings to move the ring gear towards the pinion
or away depending on weather clearance is excessive or
too little.
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Backlash and gear mesh can also be checked by using gear
paint on a section of ring gear. Rotate the gear and observe
the contact pattern on the ring gear teeth. Use shims
to move the gear assembly to the left or right depending
on whether the contact is inward on the tooth or outward.
The Ford or Chilton manuals give good instructions on
how to interpret the patterns. |

The axles can now go back into the housing assembly. |

Reinstall the axle retaining c-clips. |

Drive the pinion shaft through the differential and reinstall
the retaining bolt. Torque the bolt to 20-30 lb-ft. |

Fill the case with two quarts of gear oil and use a 4
oz. bottle of Ford friction modifier (C8AZ-19B546-A),
especially if you rebuilt the clutch packs. |

Clean and reinstall the differential cover. A bead of
silicone is preferable to a paper gasket. |

The housing assembly is rolled back under the car and
control arms, springs, calipers and sway bar go back in
place. |

Before roasting the rubber, allow the gear-set to break
in by driving for 15-20 minutes at 2500 rpm, then stopping
and allow the gears to cool completely.  |
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