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Home >> Audi >> 2010 >> S4 Automatic DCT >> Repair and Diagnosis >> External Pages >> Different car >> Section 1068 (Rear Drive Axle Differential - Vehicles With: Ford 9.75 Inch Ring Gear) >> Removal And Installation >> Drive Pinion >> Installation

Drive Pinion: Installation

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  1. NOTE: Make sure the drive pinion bearing cups are seated correctly or damage to the components may occur.

    Using the special tools, install the new inner and new outer drive pinion bearing cups. Use Special Service Tool: 205-024 (T67P-4616-A) Installer, Drive Pinion Bearing Cup., 205-852 Inner Pinion Bearing Cup Installer., 308-391 Installer, Input Shaft Bearing Cup.

    GFD271733Courtesy of FORD MOTOR COMPANY
  2. NOTE: Use the same drive pinion bearings and the drive pinion bearing adjustment shim from the drive pinion bearing adjustment shim selection procedure for final assembly or damage to the component may occur.
    NOTE: Install new drive pinion bearings without any additional lubricant since the anti-rust oil provides adequate lubricant without upsetting the drive pinion bearing preload settings.

    Assemble the special tools and new bearings in the differential housing. Use Special Service Tool: 205-159 (T80T-4020-F42) Adapter for 205-S156 Pinion Depth Gauge., 205-160 (T80T-4020-F43) Adapter for 205-S156 Pinion Depth Gauge., 205-383 (T97T-4020-B) Depth Gauge/Aligner, Drive Pinion., 205-937 Adapter, Pinion Aligning.

    GFD271734Courtesy of FORD MOTOR COMPANY
    • NOTE: This step duplicates final drive pinion bearing preload

      Tighten the special tool to the specified torque. Use Special Service Tool: 205-111 (T76P-4020-A11) Handle.

      Torque: 18 lb.in (2 Nm)

    • Slowly rotate and record the rotational torque readings.

    GFD271735Courtesy of FORD MOTOR COMPANY
  4. NOTE: Position the Adapter so it does not contact the housing.
    NOTE: Offset the Adapter to obtain an accurate reading.

    Rotate the adapter several half turns to seat the drive pinion bearings and position the adapter.

    GFD271736Courtesy of FORD MOTOR COMPANY
    • Position the special tool. Use Special Service Tool: 205-377 (T97T-4020-A) Gauge Tube, Drive Pinion., 205-159 (T80T-4020-F42) Adapter for 205-S156 Pinion Depth Gauge., 307-003 (T57L-500-B) Holding Fixture, Transmission.

    • Install the differential bearing caps and differential bearing cap bolts.

      Torque: 83 lb.ft (112 Nm)

    GFD271737Courtesy of FORD MOTOR COMPANY
  6. NOTE: Drive pinion bearing adjustment shims must be flat and clean.
    NOTE: A slight drag should be felt for correct drive pinion bearing adjustment shim selection. Do not attempt to force the drive pinion bearing adjustment shim between the gauge block and the gauge tube. This will minimize selection of a drive pinion bearing adjustment shim thicker than required, which results in a deep tooth contact in the final assembly of integral axle assemblies.

    Use a drive pinion bearing adjustment shim as a gauge for drive pinion bearing adjustment shim selection. Use Special Service Tool: 205-377 (T97T-4020-A) Gauge Tube, Drive Pinion., 205-159 (T80T-4020-F42) Adapter for 205-S156 Pinion Depth Gauge., 307-003 (T57L-500-B) Holding Fixture, Transmission.

    GFD271738Courtesy of FORD MOTOR COMPANY
    • NOTE: The differential bearing caps need to stay in the correct orientation for installation.

      Remove the differential bearing cap bolts and differential bearing caps, remove the special tools. Use Special Service Tool: 205-377 (T97T-4020-A) Gauge Tube, Drive Pinion.

    GFD271739Courtesy of FORD MOTOR COMPANY
  8. Remove the special tool. Use Special Service Tool: 205-111 (T76P-4020-A11) Handle.
    GFD271740Courtesy of FORD MOTOR COMPANY
  9. Remove the special tools. Use Special Service Tool: 205-159 (T80T-4020-F42) Adapter for 205-S156 Pinion Depth Gauge., 205-383 (T97T-4020-B) Depth Gauge/Aligner, Drive Pinion., 205-937 Adapter, Pinion Aligning., 205-160 (T80T-4020-F43) Adapter for 205-S156 Pinion Depth Gauge.
    GFD271741Courtesy of FORD MOTOR COMPANY
  10. NOTE: The differential bearing caps need to stay in the correct orientation for installation.

    Install the drive pinion inner bearing and selected drive pinion bearing adjustment shim until they are firmly seated on the drive pinion. Use Special Service Tool: 205-090 (T75L-1165-B) Plate, Bearing/Oil Seal., 205-488 Installer, Drive Pinion Bearing. Use the General Equipment: Hydraulic Press.

    GFD271742Courtesy of FORD MOTOR COMPANY
  11. Remove the special tools. Use Special Service Tool: 205-090 (T75L-1165-B) Plate, Bearing/Oil Seal., 205-488 Installer, Drive Pinion Bearing.
    GFD271743Courtesy of FORD MOTOR COMPANY
  12. Install the new drive pinion collapsible spacer.
    GFD271744Courtesy of FORD MOTOR COMPANY
  13. Install the new outer differential pinion bearing, differential outer differential pinion shim and the differential pinion.
    GFD271745Courtesy of FORD MOTOR COMPANY
  14. NOTE: When installing the drive pinion flange and pinion nut with no differential carrier installed, the drag torque (torque to turn) should be 2 to 3 Nm (16-29 in-lbs).

    Install the drive pinion seal. Refer to: Drive Pinion Seal .

  15. Install the differential carrier. Refer to: Differential Carrier .
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