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Home >> Ford >> 2000 >> Contour SE, 2.0 3, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 309 (Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear -- F150) >> In-Vehicle Repair >> Drive Pinion >> Installation

Drive Pinion: Installation

WARNING: This page is about a different car, the 2002 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.

Using 205-024 

  1. Position the special tool and the inner and outer bearing cups in their respective bores.
    1. After placing the inner and outer bearing cups in their bores, place the special tool (inner) on the inner pinion bearing cup.
    2. Place the special tool (outer) on the outer pinion bearing cup.
    3. Install the special tool.
      Fig 1: Positioning Special Tool And Inner And Outer Bearing Cups
      G02192494Courtesy of FORD MOTOR CO.
  2. Tighten the special tool to seat the pinion bearing cups into their bores.
    Fig 2: Tightening Special Tool To Seat Pinion Bearing Cups Into Their Bores
    G02192495Courtesy of FORD MOTOR CO.

    Using 205-D055 and 205-153 

  3. Drive the outer pinion bearing cup into the rear axle housing using the special tools.
    Fig 3: Driving Outer Pinion Bearing Cup Into Rear Axle Housing Using Special Tools
    G02192496Courtesy of FORD MOTOR CO.
  4. Using the special tools, drive the inner pinion bearing cup into the axle housing.
    Fig 4: Installing Inner Pinion Bearing Cup Into Axle Housing
    G02192497Courtesy of FORD MOTOR CO.

    Setting pinion depth 

    5. CAUTION: Whenever new cups are installed, new pinion bearings must also be installed.
    NOTE: If a feeler gauge can be inserted between a cup and the bottom of its bore at any point around the cup, the cup is not correctly seated.
    Fig 5: Checking Correct Seating Of Cups
    G02192498Courtesy of FORD MOTOR CO.
  5. Make sure the cups are correctly seated in their bores.
    6. NOTE: Apply only a light oil film on the pinion bearings before assembling the tools.
    Fig 6: Assembling And Positioning Special Tools
    G02192499Courtesy of FORD MOTOR CO.
  6. Assemble and position the special tools.
    7. NOTE: This step duplicates final pinion bearing preload.
    Fig 7: Identifying Tightening Torque Of Bolt
    G02192500Courtesy of FORD MOTOR CO.
  7. Tighten the special tool to the specification shown.
    8. NOTE: The special tool must be offset to obtain an accurate reading.
    Fig 8: Identifying Angle Of Rotation Of Special Tool For Correct Seating Of Pinion Bearing
    G02192501Courtesy of FORD MOTOR CO.
  8. Rotate the special tool several half-turns to make sure of correct seating of the pinion bearings and position the special tool.
  9. Install the special tool.
    1. Position the special tool.
    2. Install the differential side bearing caps.
    3. Install the four differential side bearing cap bolts.
      Fig 9: Identifying Tightening Torque Of Differential Side Bearing Cap Bolts
      G02192502Courtesy of FORD MOTOR CO.
    10. NOTE: Drive pinion bearing adjustment shims must be flat and clean.
    NOTE: A slight drag should be felt for correct shim selection. Do not attempt to force the pinion shim between the Gauge Block and the Gauge Tube. This will minimize selection of a pinion shim thicker than required, which results in a deep tooth contact in final assembly of integral rear axle assemblies.
  10. Use a drive pinion bearing adjustment shim as a gauge for shim selection.
    • After the correct shim thickness has been determined, remove the Gauge Tube.
      Fig 10: Locating Pinion Bearing Adjustment Shim
      G02192503Courtesy of FORD MOTOR CO.
  11. Using the special tool, press the pinion bearing and pinion shim until it is firmly seated on the pinion.
    Fig 11: Pressing Pinion Bearing And Pinion Shim
    G02192504Courtesy of FORD MOTOR CO.
  12. Place a new drive pinion collapsible spacer on the pinion shaft against the pinion stem shoulder.
    Fig 12: Installing Drive Pinion Collapsible Spacer On Pinion Shaft
    G02192505Courtesy of FORD MOTOR CO.
    13. CAUTION: Installation without the correct tool can result in early seal failure. If the rear axle drive pinion seal becomes cocked during installation, remove it and install a new one.
  13. Install a new rear axle drive pinion seal.
    1. Install the front pinion bearing cone and roller.
    2. Install the rear axle drive pinion shaft oil slinger in the rear axle housing.
    3. Install the rear axle drive pinion seal on the special tool.
      Fig 13: Installing Rear Axle Drive Pinion Seal On Special Tool
      G02192506Courtesy of FORD MOTOR CO.
    14. NOTE: Coat the lips of the rear axle drive pinion seal with Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.
    Fig 14: Placing Special Tool In Rear Axle Drive Pinion Seal Bore
    G02192507Courtesy of FORD MOTOR CO.
  14. Place the special tool in the rear axle drive pinion seal bore, and drive the rear axle drive pinion seal into place.
  15. From inside the rear axle housing, install the drive pinion assembly into the rear axle bore.
    Fig 15: Installing Drive Pinion Assembly Into Rear Axle Bore
    G02192508Courtesy of FORD MOTOR CO.
  16. Lubricate the pinion flange splines with rear axle lubricant.
    17. NOTE: Disregard the scribe marks if a new pinion flange is being installed.
    Fig 16: Aligning Pinion Flange With Drive Pinion Shaft
    G02192509Courtesy of FORD MOTOR CO.
  17. Align the pinion flange with the drive pinion shaft.
  18. With the drive pinion in place in the rear axle housing, install the pinion flange using the special tool.
    Fig 17: Installing Pinion Flange Using Special Tool
    G02192510Courtesy of FORD MOTOR CO.
  19. Position the new pinion nut.
    Fig 18: Installing Pinion Nut
    G02192511Courtesy of FORD MOTOR CO.
    20. CAUTION: Under no circumstances is the pinion nut to be backed off to reduce preload. If reduced preload is required, a new collapsible spacer and pinion nut must be installed.
    CAUTION: Remove the special tool while taking preload readings with the Nm (inch-pound) torque wrench.
  20. Using the special tool, hold the pinion flange and tighten the pinion nut.
    • Rotate the pinion occasionally to make sure the cone and roller bearings are seating correctly.
    • Install a Nm (inch-pound) torque wrench on the pinion nut.
    • Rotating the pinion through several revolutions, take frequent cone and roller bearing torque preload readings until the original recorded preload reading is obtained.
      Fig 19: Tightening Pinion Nut
      G02192512Courtesy of FORD MOTOR CO.
  21. Install the differential case in the rear axle differential. Refer to DIFFERENTIAL CASE .
    • If additional adjustments are necessary, Refer to DRIVELINE SYSTEM - GENERAL INFORMATION .
    22. CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion flange pilot. To make sure that the yoke seats squarely on the flange, tighten the bolts evenly in a cross pattern as shown.
    Fig 20: Identifying Tightening Torque Of Driveshaft Bolts
    G02192513Courtesy of FORD MOTOR CO.
  22. Install the driveshaft.
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