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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1539 (Rear Drive Axle/Differential - DANA 80 -- F350 Super Duty) >> In-Vehicle Repair >> Differential Ring And Pinion >> Installation

Differential Ring And Pinion: Installation

WARNING: This page is about a different car, the 2006 Ford Pickup and 2006 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. Position the inner and outer pinion bearing cups and the special tools in their respective axle housing bores.
    1. After placing the inner and outer pinion 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 (drawbar).
      Fig 1: Identifying Special Tool
      G04643575Courtesy of FORD MOTOR CO.
  2. Tighten the special tool to seat the pinion bearing cups into their bores.
    Fig 2: Identifying Special Tool
    G04643576Courtesy of FORD MOTOR CO.
    3. NOTE: If the feeler gauge can fit between a pinion bearing cup and the bottom of its bore at any point around the pinion bearing cup, remove and reseat the pinion bearing cup.
    Fig 3: Checking Clearance Between Cup And Bore
    G03878664Courtesy of FORD MOTOR CO.
  3. Check that the pinion bearing cups have seated correctly in their bores.
    4. NOTE: Apply Threadlock and Sealer to the 2 new differential ring gear bolts.
    NOTE: If removed, install the anti-lock speed sensor ring.
    Fig 4: Locating Differential Ring Gear Bolts
    G04643578Courtesy of FORD MOTOR CO.
  4. Start 2 bolts through the differential case flange, the anti-lock sensor ring and into the differential ring gear to make sure the differential ring gear and the differential case align.
  5. Press the anti-lock speed sensor ring and differential ring gear on the differential carrier. The differential carrier flange acts as a pilot for the anti-lock speed sensor ring.
    Fig 5: Pressing Ring Gear And Anti-Lock Speed Sensor Ring Onto Differential Case
    G03883502Courtesy of FORD MOTOR CO.
  6. Apply Threadlock and Sealer and install the 10 remaining bolts alternately and evenly.
    • Tighten to 298 Nm (220 lb-ft).
      Fig 6: Identifying Ring Gear Bolts
      G03883503Courtesy of FORD MOTOR CO.
  7. Install the original outboard spacers in the side from which they were removed.
    Fig 7: Identifying Outboard Spacers
    G03883404Courtesy of FORD MOTOR CO.
    8. NOTE: Remove all nicks, burrs and dirt from the differential carrier hubs to allow the differential bearings to rotate freely.
    Fig 8: Identifying Special Tool On Differential Carrier Hubs
    G04643582Courtesy of FORD MOTOR CO.
  8. Place the 0.762 mm (0.030 in) inboard shim and the special tool on the differential carrier hubs. Position the differential carrier into the axle housing.
    9. NOTE: Use a dial indicator with a minimum travel capability of 5.08 mm (0.200 in).
    Fig 9: Identifying Special Tool
    G04643583Courtesy of FORD MOTOR CO.
  9. Mount the special tools as shown. Locate the tip of special tool on the flat surface of one of the differential ring gear bolts.
    10. NOTE: Repeat this step and the following step until the same reading appears on the indicator each time. Record the reading. This is the total differential outboard bearing spacer thickness required, less preload. The final calculation occurs later during assembly.
    Fig 10: Checking Differential Carrier End Play
    G04643584Courtesy of FORD MOTOR CO.
  10. Force the differential carrier as far as possible toward the indicator. With force still applied, zero the indicator.
  11. Force the differential carrier as far as it will go in the opposite direction. Record the total differential carrier end play reading.
    Fig 11: Checking Differential Carrier End Play
    G04643585Courtesy of FORD MOTOR CO.
  12. After making sure the reading is correct, remove the special tools and the differential carrier from the axle housing. Do not remove the master bearings or the bearing shims from the differential carrier at this time.
    13. CAUTION: If any of the gauge surfaces have nicks in them, remove the high spots with a medium India oilstone to prevent erroneous readings.
    NOTE: Apply a light oil film on the pinion bearings before assembling the tools.
  13. Assemble and position the following in the differential housing.
    1. Position the special tool.
    2. Position the special tool.
    3. Position the inner pinion bearing.
    4. Position the special tool.
    5. Position the special tool.
    6. Position the outer pinion bearing.
    7. Thread on the special tool.
      Fig 12: Identifying Special Tool
      G04643586Courtesy of FORD MOTOR CO.
  14. Install the special tool.
    1. Install the differential bearing caps.
    2. Install the differential bearing cap bolts.
      • Tighten to 108 Nm (80 lb-ft).
        Fig 13: Identifying Special Tool
        G04643587Courtesy of FORD MOTOR CO.
  15. Inspect the drive pinion bearing preload shim for damage. Discard it if necessary. New drive pinion bearing preload shims are available in the thickness shown in the following chart.
    AVAILABLE INNER DRIVE PINION BEARING SHIMS

    mm Inches
    0.36 0.014
    0.38 0.015
    0.41 0.016
    0.46 0.018
    0.51 0.020
    0.53 0.021
    0.56 0.022
    0.58 0.023
    0.76 0.030
    16. NOTE: Use a feeler gauge or flat, clean drive pinion position shim as a measuring device.
    NOTE: Do not attempt to force the gauge or drive pinion position shim between the special tools. A slight drag indicates a correct selection.
  16. Using a feeler gauge or flat, clean drive pinion position shim, measure between the special tools. Record the measurement.
    • Remove the special tools after making the correct drive pinion position shim selection.
      Fig 14: Placing Drive Pinion Bearing Adjustment Shim Between Gauge Block And Gauge Tube
      G03878604Courtesy of FORD MOTOR CO.
  17. Notice the (+) or (-) etching on both the old and new pinion, and adjust the new shim thickness to compensate for the difference of these 2 figures. If so equipped, include the oil slinger thickness in the total measurement to correctly set pinion depth.
    • For example, a pinion etched with m+8 (+3) requires 0.08 mm (0.003 in) less shimming than a pinion etched "0". This means to increase the mounting distance by the amount etched in the pinion, subtract 0.08 mm (0.003 in) from the drive pinion position shim selected for installation. A pinion etched m-8 (-3), requires 0.08 mm (0.003 in) more shimming than a pinion etched "0". In this instance, add 0.08 mm (0.003 in) to the drive pinion position shim selected for installation to decrease the pinion mounting distance by the amount etched in the pinion.
    18. NOTE: Always use the same new inner pinion bearing installed when taking the measurement for drive pinion shim selection.
    NOTE: Position the selected pinion depth shim on the pinion shaft between the inner bearing and the pinion head.
    Fig 15: Locating Pinion Bearing
    G04643589Courtesy of FORD MOTOR CO.
  18. Using the special tools and a suitable press, install the pinion bearing.
  19. Position the original pinion bearing preload shims on the pinion and install the pinion gear in the pinion gear bore from the rear of the housing.
  20. Install the outer pinion bearing and drive pinion oil slinger.
    21. NOTE: The pinion flange must never be hammered on or installed with power tools.
    Fig 16: Identifying Special Tool For Pinion Flange
    G04643590Courtesy of FORD MOTOR CO.
  21. Using the special tool, install the pinion flange.
  22. Use the special tool to prevent the pinion flange from turning while installing the old washer and the pinion nut.
    • Tighten to 637 Nm (470 lb-ft).
      Fig 17: Holding Pinion Flange With Special Tool
      G03883491Courtesy of FORD MOTOR CO.
  23. Using a Nm (lb-in) torque wrench, rotate the pinion. The rotational torque must read 2.9-5.0 Nm (25-45 lb-in).
    • To increase the drive pinion bearing preload, remove drive pinion bearing preload shims. To decrease the drive pinion bearing preload, add drive pinion bearing shims.
      Fig 18: Checking Pinion Rotational Torque
      G03918456Courtesy of FORD MOTOR CO.
  24. While using a suitable tool to prevent the pinion flange from turning, remove and discard the old washer and pinion nut.
    Fig 19: Holding Pinion Flange With Special Tool
    G03883491Courtesy of FORD MOTOR CO.
  25. Using the special tool, remove the pinion flange.
    Fig 20: Removing Pinion Flange Using Special Tool
    G03878593Courtesy of FORD MOTOR CO.
    26. CAUTION: If the drive pinion seal becomes cocked during installation, remove and install a new one. Make sure the garter spring remains in place during assembly. If the spring is dislodged, a new drive pinion seal must be installed.
  26. Using a suitable tool, drive the pinion seal into the housing.
    • Coat the pinion seal (rubber lips) with axle lubricant.
      Fig 21: Driving Pinion Seal Into Housing Using Special Tool
      G04643595Courtesy of FORD MOTOR CO.
    27. NOTE: The pinion flange must never be hammered on or installed with power tools.
    Fig 22: Checking Pinion Rotational Torque
    G03918456Courtesy of FORD MOTOR CO.
  27. Using the special tool, install the pinion flange.
  28. Using the special tool, prevent the pinion flange from turning while installing the new washer and pinion nut.
    • Tighten to 637 Nm (470 lb-ft).
      Fig 23: Holding Pinion Flange With Special Tool
      G03883491Courtesy of FORD MOTOR CO.
  29. Using a Nm (lb-in) torque wrench, rotate the pinion. The rotational torque must read 0.6 Nm (5 lb-in) higher with the new pinion seal installed.
    Fig 24: Checking Pinion Rotational Torque
    G03918456Courtesy of FORD MOTOR CO.
  30. Position the differential carrier assembly with the special tools and inner bearing shims in the axle housing. Install the special tools and locate the tip of special tool 308-021 on a flat surface.
    Fig 25: Identifying Special Tool
    G04643599Courtesy of FORD MOTOR CO.
  31. Force the differential case away from the drive pinion. With force still applied, set the indicator to zero.
    Fig 26: Checking Differential Carrier End Play
    G04643600Courtesy of FORD MOTOR CO.
    32. NOTE: Repeat this step and the preceding step until the same reading appears on the indicator each time. This is the differential outboard bearing shim thickness increase necessary between the differential bearing and the LH side of the differential case.
    Fig 27: Checking Differential Carrier End Play
    G04643601Courtesy of FORD MOTOR CO.
  32. Force the differential ring gear into mesh with the pinion to obtain the indicator reading. Record the reading.
  33. Remove the differential case from the differential housing.
    Fig 28: Identifying Special Tool
    G04643602Courtesy of FORD MOTOR CO.
  34. Remove the master bearings from the differential case.
    • Make sure the inner bearing shims remain on the differential carrier hubs.
  35. Using the special tool, install the differential bearing and shim on the LH side of the differential case.
    Fig 29: Identifying Special Tool For Differential Bearing Installation
    G03883526Courtesy of FORD MOTOR CO.
  36. Using the special tools, install the differential bearing.
    1. Place the special tool on the differential bearing to protect it during the installation of the opposite bearing.
    2. Using the special tool, drive the differential bearing onto the hub.
      Fig 30: Identifying Special Tool
      G04643604Courtesy of FORD MOTOR CO.
  37. Assemble the differential bearing cups to the differential bearings.
  38. Place one outboard spacer of the necessary thickness, as determined from the previous measurement, on the LH side of the differential housing.
  39. Determine the correct outboard spacer thickness and place it on the differential case hub on the RH side.
    • To determine the correct spacer thickness, first, subtract the reading of the previous measurement from the total differential case end play reading. Then, add 0.25 mm (0.010 in) to this amount. This is the correct thickness spacer to place on RH side of the housing.
    40. CAUTION: Do not spread the differential housing more than specified.
    CAUTION: Avoid nicking the ring gear teeth and the anti-lock speed sensor ring during assembly.
  40. Using the special tools, spread the differential housing to the specification.
    • Use a rawhide hammer to seat the differential into the differential housing pocket.
      • Remove the special tools.
        Fig 31: Using Special Tool To Spread Differential Housing
        G03918287Courtesy of FORD MOTOR CO.
    41. NOTE: Match the mating letters as noted during disassembly.
  41. Install the 2 bearing caps and 4 bolts, aligning the letters with those on the differential housing.
    • Tighten to 108 Nm (80 lb-ft).
      Fig 32: Locating Differential Bearing Caps
      G04414224Courtesy of FORD MOTOR CO.
  42. Confirm the total preload.
    • Using a Nm (lb-in) torque wrench, check the torque to rotate the pinion. The reading must be higher than the initial reading (taken without the differential carrier installed) with new bearings installed as recommended by the following:
      • 3.54 and 3.73 = 0.9 Nm (8 lb-in)
      • 4.10 and 4.56 = 0.8 Nm (7 lb-in)
      • 4.63 and 5.13 = 0.8 Nm (7 lb-in)
    • If the total preload is too high, remove an equal amount of differential bearing shims from each differential case hub. If the total preload is too low, add an equal amount of differential bearing shims to each differential case hub.
      Fig 33: Checking Pinion Rotational Torque
      G03918456Courtesy of FORD MOTOR CO.
  43. Using the special tools, measure the differential ring gear and pinion backlash at 3 equally spaced points.
    Fig 34: Measuring Differential Ring Gear & Pinion Backlash Using Special Tools
    G03918386Courtesy of FORD MOTOR CO.
  44. Carry out the tooth contact pattern check to verify the final pinion position is correct. For additional information, refer to REAR DRIVE AXLE AND DIFFERENTIAL  in the Diagnosis and Testing portion of this section.
  45. Install the axle shafts. For additional information, refer to WHEEL HUBS AND BEARINGS - FULL FLOATING AXLE - DANA .
    46. NOTE: Align the index marks made during removal.
  46. Connect the driveshaft flange and the axle flange and install the 4 bolts.
    • Tighten to 136 Nm (100 lb-ft).
      Fig 35: Locating Index-Mark On Driveshaft Flange & Pinion Flange
      G03884149Courtesy of FORD MOTOR CO.
    47. NOTE: Install the differential cover within 15 minutes of applying the silicone or it will be necessary to remove and reapply new sealant.
    Fig 36: Proper Application Of Sealant To Differential Housing Cover
    G03878622Courtesy of FORD MOTOR CO.
  47. Apply a continuous bead of sealant of the specified thickness to the differential housing cover.
  48. Place 2 bolts into the differential housing cover at the 8 o'clock and 2 o'clock positions. Install the differential housing cover on the differential housing.
  49. Install the 8 remaining bolts. Tighten the bolts alternately and evenly.
    • Tighten to 47 Nm (35 lb-ft).
    • If possible, allow an hour cure time before filling the axle with the correct amount of specified lubricant.
  50. Fill the axle with the specified type and amount of fluid.
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