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Home >> Ford >> 2000 >> Contour SE, 2.0 3, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 366 (Rear Drive Axle/Differential - Ford 8.8- Inch Ring Gear) >> In-Vehicle Repair >> Drive Pinion >> Installation

Drive Pinion: Installation

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    NOTE: This step and the following step show the preferred method for installing the pinion bearing cups. An alternate method is shown following these two steps.
    Fig 1: Positioning Special Tools And Inner And Outer Bearing Cups
    G01948113Courtesy of FORD MOTOR CO.
  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 (inner) on the inner pinion bearing cup.
    2. Place the special tool (outer) on the outer pinion bearing cup.
    3. Install the special tool.
  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 Bores
    G01948114Courtesy of FORD MOTOR CO.
    3. NOTE: This step and the following step are alternate methods for installing the pinion bearing cups. Carry out these two steps if pinion bearing cup installation was not done in the previous steps.
    Fig 3: Installing Outer Pinion Bearing Cup Into Rear Axle Housing
    G01948115Courtesy of FORD MOTOR CO.
  3. Using the special tools, drive the outer pinion bearing cup into the rear axle housing.
  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
    G01948116Courtesy of FORD MOTOR CO.
    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: Inserting Feeler Gauge Between Cup And Bottom Of Bore
    G01948117Courtesy 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: Installing Special Tools
    G01948118Courtesy of FORD MOTOR CO.
  6. Assemble and position the special tools.
    7. NOTE: This step duplicates final pinion bearing preload.
    Fig 7: Tightening Special Tool
    G01948119Courtesy 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: Rotating Special Tool Several Half-Turns
    G01948120Courtesy 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: Installing Four Differential Side Bearing Cap Bolts
    G01948121Courtesy 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.
    Fig 10: Identifying Drive Pinion Bearing Adjustment Shim
    G01948122Courtesy of FORD MOTOR CO.
  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 tool.
  11. Using the special tools, press the pinion bearing and pinion shim until seated firmly on the pinion.
    Fig 11: Pressing Pinion Bearing And Pinion Shim
    G01948123Courtesy of FORD MOTOR CO.
  12. Place a new drive pinion collapsible spacer (4662) on the pinion shaft against the pinion stem shoulder.
    Fig 12: Placing Drive Pinion Collapsible Spacer On Pinion Shaft
    G01948124Courtesy 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: Identifying Rear Axle Drive Pinion Seal Components
    G01948125Courtesy of FORD MOTOR CO.
  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.
    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 In Seal Bore
    G01948126Courtesy 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 (4010), install the drive pinion assembly (drive pinion, shims, rear bearing cone and roller, and drive pinion collapsible spacer) into the rear axle bore.
    Fig 15: Installing Drive Pinion In Rear Axle Bore
    G01948127Courtesy 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
    G01948128Courtesy 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
    G01948129Courtesy of FORD MOTOR CO.
  19. Position the new pinion nut.
    Fig 18: Positioning Pinion Nut
    G01948130Courtesy 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.
    Fig 19: Holding Pinion Flange With Special Tool
    G01948131Courtesy of FORD MOTOR CO.
  20. Using the special 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. For additional information, refer to TORQUE SPECIFICATIONS .
  21. Position the rear driveshaft and align the marks on the pinion flange.
    Fig 20: Aligning Marks On Pinion Flange
    G01948132Courtesy of FORD MOTOR CO.
    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 21: Installing Driveshaft To Pinion Flange Bolts
    G01948133Courtesy of FORD MOTOR CO.
  22. Install the bolts and tighten to specification.
  23. Install the differential case in the rear axle differential. For additional information, refer to DIFFERENTIAL CASE .
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