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Home >> Ford >> 2000 >> Contour SE, 2.0 3, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 310 (Rear Drive Axle/Differential - Ford 9.75-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 tools 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 on the inner pinion bearing cup.
    2. Place the special tool on the outer pinion bearing cup.
    3. Install the special tools.
      Fig 1: Placing Special Tool On Outer Pinion Bearing Cup
      G02195885Courtesy 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
    G02195886Courtesy of FORD MOTOR CO.

    Using 205-D055 and 205-153

  3. Drive the outer pinion bearing cup into the rear axle housing (4010), using the special tools.
    Fig 3: Installing Outer Pinion Bearing Cup Into Rear Axle Housing
    G02195887Courtesy of FORD MOTOR CO.
  4. Using the special tools, drive the inner pinion bearing cup into the rear axle housing.
    Fig 4: Installing Inner Pinion Bearing Cup Into Rear Axle Housing
    G02195888Courtesy of FORD MOTOR CO.

    Setting pinion depth

    5. CAUTION: Whenever new cups are installed, new differential pinion bearings must also be installed.
    NOTE: If a feeler gauge of the specification shown in the illustration 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: Measuring Gap Between Cup And Bottom Of Bore
    G02195889Courtesy 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 tool.
    Fig 6: Identifying Parts Of Special Tools For Assembling
    G02195890Courtesy of FORD MOTOR CO.
  6. Assemble and position the special tools.
  7. Tighten the special tool to the specified rotational torque.
    Fig 7: Tightening Special Tool To Specified Rotational Torque
    G02195891Courtesy of FORD MOTOR CO.
    8. NOTE: The special tool must be offset to obtain an accurate reading.
    Fig 8: Rotating Special Tool Several Half-Turns For Checking Correct Seating Of Pinion Bearings
    G02195892Courtesy of FORD MOTOR CO.
  8. Rotate the special tool several half-turns to make sure of correct seating of the pinion bearings, then position the special tool.
  9. Install the special tool.
    1. Position the special tool.
    2. Install the differential side bearing caps.
    3. Install the differential side bearing cap bolts.
      Fig 9: Installing Differential Side Bearing Cap
      G02195893Courtesy 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 the 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 special tools.
      Fig 10: Identifying Drive Pinion Bearing Adjustment Shims
      G02195894Courtesy of FORD MOTOR CO.
  11. Using the special tools, press the pinion bearing and pinion shim until they are firmly seated on the pinion.
    Fig 11: Installing Pinion Bearing And Pinion Shim On Pinion
    G02195895Courtesy of FORD MOTOR CO.
  12. Place a new drive pinion collapsible spacer (4662) on the pinion shaft against the pinion stem shoulder.
    Fig 12: Installing Drive Pinion Collapsible Spacer
    G02195896Courtesy 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.
    Fig 13: Installing Rear Axle Drive Pinion Shaft Oil Slinger
    G02195897Courtesy of FORD MOTOR CO.
  13. Install a new outer pinion bearing, rear axle drive pinion seal and rear axle drive pinion shaft oil slinger.
    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: Installing Rear Axle Drive Pinion Seal
    G02195898Courtesy of FORD MOTOR CO.
  14. Place the special tool in the pinion seal bore and drive the rear axle drive pinion seal into place.
  15. Install the drive pinion in the drive pinion carrier bore from inside the rear axle housing (4010). Seat the drive pinion with a plastic hammer.
    Fig 15: Installing Drive Pinion In Drive Pinion Carrier Bore From Inside Rear Axle Housing
    G02195899Courtesy of FORD MOTOR CO.
  16. Lubricate the pinion flange splines.
    • Use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.
    17. NOTE: Disregard the scribe marks if a new pinion flange is being installed.
    Fig 16: Aligning Pinion Flange With Drive Pinion Shaft
    G02195900Courtesy of FORD MOTOR CO.
  17. Align the pinion flange with the drive pinion shaft.
  18. With the drive pinion in place in the axle housing, install the pinion flange using the special tool.
    Fig 17: Installing Pinion Flange
    G02195901Courtesy of FORD MOTOR CO.
  19. Position the new pinion nut.
    Fig 18: Installing Pinion Nut
    G02195902Courtesy 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 drive pinion collapsible spacer and pinion nut must be installed.
    CAUTION: The pinion flange holding tool must be removed before preload readings can be taken.
    Fig 19: Holding Pinion Flange With Pinion Flange Holding Tool For Tightening Pinion Nut
    G02195903Courtesy of FORD MOTOR CO.
  20. Using a suitable pinion flange holding tool to hold the pinion flange, 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.
    • If the original recorded preload is lower than specifications, tighten to the appropriate specifications for used bearings. If the preload is higher than specification, tighten the nut to the original reading as recorded. Refer to TORQUE SPECIFICATIONS .
  21. Install the differential case. Refer to DIFFERENTIAL CASE . For additional adjustments, Refer to DRIVELINE SYSTEM - GENERAL INFORMATION .
  22. Position the driveshaft and align the mark on the pinion flange.
    Fig 20: Positioning Driveshaft And Aligning Mark On Pinion Flange
    G02195904Courtesy of FORD MOTOR CO.
    23. 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 21: Installing Driveshaft
    G02195905Courtesy of FORD MOTOR CO.
  23. Install the driveshaft.
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