2006 Ford F-150 Repair Question
Ford F-150 Axle Problem
There are different axles but none of them are do-it-yourselfer projects. Anyone can unbolt stuff and pull parts out but setting up the bearing preload, ring gear backlash, and side gear clearance requires special tools and procedures. Some axles require a housing spreader to get the differential assembly out and back in. Over-stretching the housing can permanently distort it.
Pinion gear depth and bearing side clearance must be carefully adjusted. You'll need a shim kit and you'll have to install the pinion gear numerous times with different select-fit shims to get it right. All of these adjustments affect the tooth contact pattern which has to be checked. If the contact pattern is wrong, you will have noise right away, after many miles, and / or only when accelerating or coasting.
Setting up a differential is a specialty field that few professionals are experienced enough to handle.
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