Posted by Brizey
I would suggest saving or printing this off as things tend to get lost on here.
Read it through a couple of times to familiarize yourself with the gasket colour/thicknesses.
This is the same as in the Ford manuals, but i just wrote it in laymans terms to, hopefully, make it easier to understand...
1, bolt the right hand axle housing to the banjo, using an .009 gasket (pale blue),
five bolts are fine. This should include the diff/axle unit.
2, stand this assembly on end (it needs to be off the floor, maybe held
in a vice or just supported in anything that will hold it OFF the floor,
3, fit the left hand axle housing over the shaft so it seats on the diff
bearing, insert five bolts to locate the housing, these bolts are just to
locate the housing, so DO NOT tighten (no gasket is needed at this point),
check the housing is seated properly on the diff bearing.
4, you should be able to see a small gap between the left housing and the
banjo, insert a feeler gauge into this gap, check in four places round the
circumference, make a note of the thickest blade you can get in there.
You need to select a gasket (or combination of different thickness gaskets) that
together total between 0.004 to 0.018 THINNER than the feeler gauge, ie: if
the thickest blade is an .020, you can use an .015 gasket, this will give the required "pinch" on the diff bearings.
You might have to swap different thickness gaskets side to side of the banjo
to achieve this, ie: you might have to replace the 010 gasket fitted in operation 1 for an 005 gasket. I had to do this operation 4 times before finding the correct combination!.
Once you have the combination of gaskets correct, keep them in order on their correct side of the housings ready for final assembly.
Gasket thicknesses are 005 (white) ....... 009 (pale blue) ....... 015 (black), i ended up using an 015 (L) and an 005 (R), though this could be totaly different for your rearend. I have seen different colour/thickness gaskets, but, the same procedure applies whatever colour/thickness your gasket set has.
When you turn the halfshafts, you are looking for a `heavy drag`, both shafts should be turned in the same direction at the same speed, so you`d probably need a friend to help here, unless you have loooong arms!.
Do`nt use silicon sealer or similar on the gaskets as this will upset the gasket thicknesses.
Clear as mud eh, sounds involved, but once you get your head round it, its not to bad.
Hope this helps..