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Home >> Ford >> 2000 >> Contour SE, 2.0 3, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 968 (Rear Drive Axle/Differential - Ford 10.25-Inch Ring Gear -- F150) >> In-Vehicle Repair >> Differential Ring and Pinion >> Installation

Differential Ring and Pinion: Installation

WARNING: This page is about a different car, the 2005 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
  1. Position the special tools and the inner and outer drive pinion bearing cups in their respective bores.
    1. After placing the inner and outer drive pinion bearing cups in their bores, place the special tool on the inner drive pinion bearing cup.
    2. Place the special tool on the outer drive pinion bearing cup.
    3. Install the special tools.
    Fig 1: Positioning Special Tools And Inner And Outer Drive Pinion Bearing Cups In Their Respective Bores
    G03904408Courtesy of FORD MOTOR CO.
  2. Tighten the special tool to seat the drive pinion bearing cups into their bores.
    Fig 2: Tightening Special Tool To Seat Drive Pinion Bearing Cups Into Their Bores
    G03960713Courtesy of FORD MOTOR CO.
  3. Make sure the drive pinion bearing cups are correctly seated in their bores.
    • If a feeler gauge of the specification shown in the illustration can be inserted between a drive pinion bearing cup and the bottom of its bore at any point around the drive pinion bearing cup, the drive pinion bearing cup is not correctly seated.
    Fig 3: Checking Clearance Between Cup And Bore Using Feeler Gauge
    G03878664Courtesy of FORD MOTOR CO.
    4. CAUTION: The special tools must be used with the new pinion bearings to be used.
    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.
    Fig 4: Installing Special Tools
    G03960645Courtesy of FORD MOTOR CO.
  4. Install the special tools.
  5. Tighten the special tool to the specified rotational torque.
    • Tighten to 2.2 Nm (20 lb-in).
    Fig 5: Tightening Special Tool To Specified Rotational Torque
    G03878601Courtesy of FORD MOTOR CO.
    6. NOTE: The special tool must be offset to obtain an accurate reading.
    Fig 6: Rotating Special Tool Several Half-Turns
    G03883649Courtesy of FORD MOTOR CO.
  6. Rotate the special tool several half-turns to make sure of correct seating of the drive pinion bearings, then position the special tool.
  7. Install the special tool.
    1. Position the special tool.
    2. Install the differential side bearing caps.
    3. Install the differential side bearing cap bolts.
      • Tighten to 105 Nm (77 lb-ft).
    Fig 7: Installing Differential Side Bearing Caps And Bolts
    G03904414Courtesy of FORD MOTOR CO.
    8. 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 special tools. 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.
    Fig 8: Using Drive Pinion Bearing Adjustment Shim As A Gauge For Drive Pinion Bearing Adjustment Shim Selection
    G03883651Courtesy of FORD MOTOR CO.
  8. Use a drive pinion bearing adjustment shim as a gauge for drive pinion bearing adjustment shim selection.
    • After the correct drive pinion bearing adjustment shim thickness has been determined, remove the special tools from the axle housing.
  9. Using a press and the special tools, press the pinion bearing until it is firmly seated on the pinion gear and the drive pinion bearing adjustment shim.
    Fig 9: Pressing Pinion Bearing Until It Is Firmly Seated On Pinion Gear And Drive Pinion Bearing Adjustment Shim
    G03904416Courtesy of FORD MOTOR CO.
  10. Place a new drive pinion collapsible spacer on the pinion gear against the pinion gear shoulder.
    Fig 10: Placing New Drive Pinion Collapsible Spacer On Pinion Gear Against Pinion Gear Shoulder
    G03878606Courtesy of FORD MOTOR CO.
  11. Install the outer drive pinion bearing and drive pinion shaft oil slinger.
    Fig 11: Installing Outer Drive Pinion Bearing And Drive Pinion Shaft Oil Slinger
    G03884436Courtesy of FORD MOTOR CO.
  12. Lubricate the new drive pinion seal with grease.
    13. CAUTION: If the new drive pinion seal becomes misaligned during installation, remove the drive pinion seal and install a new drive pinion seal.
    Fig 12: Installing Drive Pinion Seal Using Special Tool
    G03884437Courtesy of FORD MOTOR CO.
  13. Using the special tool, install a new drive pinion seal.
  14. Install the pinion gear in the pinion gear bore from inside the axle housing.
    Fig 13: Installing Pinion Gear In Pinion Gear Bore From Inside Axle Housing
    G04583053Courtesy of FORD MOTOR CO.
  15. Using the special tool, install the pinion flange.
    Fig 14: Installing Pinion Flange Using Special Tool
    G03884510Courtesy of FORD MOTOR CO.
  16. Position the new pinion nut.
    Fig 15: Positioning New Pinion Nut
    G03884298Courtesy of FORD MOTOR CO.
    17. CAUTION: Under no circumstances is the pinion nut to be backed off to reduce drive pinion bearing preload. If reduced drive pinion bearing preload is required, a new drive pinion collapsible spacer and pinion nut must be installed.
    CAUTION: Remove the special tool while taking drive pinion bearing preload readings with the Nm (lb-in) torque wrench.
    Fig 16: Using Special Tool To Hold Pinion Flange And Tightening Pinion Nut
    G03883491Courtesy of FORD MOTOR CO.
  17. Using the special tool to hold the pinion flange, tighten the pinion nut.
    • Rotate the drive pinion occasionally to make sure the drive pinion bearings are seating correctly.
    • Install a Nm (lb-in) torque wrench on the pinion nut.
    • Rotating the drive pinion through several revolutions, take frequent drive pinion bearing preload readings until the original recorded drive pinion bearing preload reading is obtained.
  18. Press the left and right differential bearing on the differential assembly.
    Fig 17: Pressing Left And Right Differential Bearing On Differential Assembly
    G03884442Courtesy of FORD MOTOR CO.
    19. NOTE: If removed, press the speed sensor ring on with the differential ring gear.
    Fig 18: Installing Differential Ring Gear
    G03884443Courtesy of FORD MOTOR CO.
  19. Install the differential ring gear.
    1. Place the differential ring gear on the differential assembly.
    2. Hand-start 3 ring gear bolts to align the holes in the differential ring gear and the differential assembly.
    3. Place the differential assembly and differential ring gear onto the press bed blocks with the differential ring gear teeth facing downward.
    4. Press the differential ring gear into place.
  20. Install the 12 differential ring gear bolts.
    • Apply stud and bearing mount to the differential ring gear bolts.
    • Tighten to 150 Nm (111 lb-ft).
    Fig 19: Installing 12 Differential Ring Gear Bolts
    G03884368Courtesy of FORD MOTOR CO.
  21. Install the differential assembly in the axle housing.
    Fig 20: Installing Differential Assembly In Axle Housing
    G03878552Courtesy of FORD MOTOR CO.
  22. Install a differential bearing shim on the LH side.
    Fig 21: Installing Differential Bearing Shim On LH Side
    G03884446Courtesy of FORD MOTOR CO.
    23. CAUTION: Index-mark the position of the differential bearing caps as arrows may not be visible. The differential bearing caps must be installed in their original locations and positions.
    NOTE: Apply pressure toward the LH side to make sure the LH differential bearing cap is seated.
    Fig 22: Identifying LH Differential Bearing Cap And Loosely Installing Differential Bearing Cap Bolts
    G03878615Courtesy of FORD MOTOR CO.
  23. Install the LH differential bearing cap and loosely install the differential bearing cap bolts.
  24. Install progressively larger differential bearing shims on the RH side until the largest differential bearing shim selected that can be installed by hand.
    Fig 23: Installing Progressively Larger Differential Bearing Shims On RH Side
    G03878555Courtesy of FORD MOTOR CO.
  25. Install the RH side differential bearing cap and tighten the LH side and RH side differential bearing cap bolts.
    • Tighten to 105 Nm (77 lb-ft).
    Fig 24: Installing RH Side Differential Bearing Cap And Tightening LH Side And RH Side Differential Bearing Cap Bolts
    G03878679Courtesy of FORD MOTOR CO.
  26. Rotate the differential assembly to make sure it rotates freely.
    Fig 25: Rotating Differential Assembly
    G03878557Courtesy of FORD MOTOR CO.
    27. NOTE: If ring gear backlash is within specification, go to Step  31.
    Fig 26: Measuring Ring Gear Backlash Using Special Tools
    G03884451Courtesy of FORD MOTOR CO.
  27. Using the special tools, measure ring gear backlash.
    28. NOTE: The differential bearing caps must be removed before differential bearing shims can be installed.
    Fig 27: Installing Thicker Differential Bearing Shim And Thinner Differential Bearing Shim
    G03884521Courtesy of FORD MOTOR CO.
  28. To increase ring gear backlash, install a thicker differential bearing shim and a thinner differential bearing shim as shown.
    • If ring gear backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness on the other differential bearing shim by the same amount.
    BACKLASH ADJUSTMENT AND DIFFERENTIAL BEARING SHIM SPECIFICATION

    Backlash Change Required Thickness Change Required
    mm in mm in
    0.025 0.001 0.050 0.002
    0.050 0.002 0.050 0.002
    0.076 0.003 0.101 0.004
    0.101 0.004 0.152 0.006
    0.127 0.005 0.152 0.006
    0.152 0.006 0.203 0.008
    0.177 0.007 0.254 0.010
    0.203 0.008 0.254 0.010
    0.228 0.009 0.304 0.012
    0.254 0.010 0.355 0.014
    0.279 0.011 0.355 0.014
    0.304 0.012 0.406 0.016
    0.330 0.013 0.457 0.018
    0.335 0.014 0.457 0.018
    0.381 0.015 0.508 0.020
  29. Rotate the differential assembly several times to make sure the differential bearings are seated.
    Fig 28: Rotating Differential Assembly
    G03878680Courtesy of FORD MOTOR CO.
  30. Using the special tools, recheck the ring gear backlash.
    Fig 29: Rechecking Ring Gear Backlash Using Special Tools
    G03884451Courtesy of FORD MOTOR CO.
  31. Remove the differential bearing cap bolts and differential bearing caps.
    Fig 30: Removing Differential Bearing Cap Bolts And Differential Bearing Caps
    G03884455Courtesy of FORD MOTOR CO.
    32. NOTE: To establish differential bearing preload, increase both left and right differential bearing shim sizes as shown. Make sure differential bearing shims are fully seated and the differential assembly turns freely.
    Fig 31: Installing Differential Bearing Shims Using Special Tool
    G03884525Courtesy of FORD MOTOR CO.
  32. Using the special tool, install the differential bearing shims.
  33. Install the differential bearing caps and differential bearing cap bolts.
    • Tighten to 105 Nm (77 lb-ft).
    Fig 32: Installing Differential Bearing Caps And Differential Bearing Cap Bolts
    G03878679Courtesy of FORD MOTOR CO.
  34. Apply marking compound and rotate the differential assembly 5 complete revolutions.
  35. Verify an acceptable pattern check.
  36. Install the axle shafts. For additional information, refer to AXLE ASSEMBLY .
  37. Position the driveshaft and align the index mark on the pinion flange.
    Fig 33: Aligning Index Mark On Pinion Flange
    G03878625Courtesy of FORD MOTOR CO.
    38. CAUTION: The driveshaft centering socket yoke fits tightly on the pinion flange pilot. To make sure that the driveshaft centering socket yoke seats squarely on the pinion flange, tighten the driveshaft flange bolts evenly in a cross pattern.
    Fig 34: Installing Driveshaft Flange Bolts
    G03878515Courtesy of FORD MOTOR CO.
  38. Install the driveshaft flange bolts.
    • Tighten to 103 Nm (76 lb-ft).
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