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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1541 (Rear Drive Axle/Differential - Ford 10.50-Inch Ring Gear -- F250-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. Install the inner and outer bearing cups.
    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 tool into the replacer tools.
      Fig 1: Using Special Tool On Inner And Outer Bearing Cups
      G04643931Courtesy of FORD MOTOR CO.
  2. Tighten the special tool to install the pinion bearing cups into their bores.
    Fig 2: Using Special Tool On Bearing Cups Bolts
    G04643932Courtesy of FORD MOTOR CO.
  3. Make sure the cups are correctly seated in their bores.
    • 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 3: Measuring Clearance Between Cup And Bottom Of Its Bore
      G03878599Courtesy of FORD MOTOR CO.
    4. 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: Identifying Drive Pinion Bearings Components
    G04643934Courtesy of FORD MOTOR CO.
  4. Assemble and position the special tools.
    MATERIAL SPECIFICATIONS

    Item Part Number Description
    1 4621 Pinion bearing (outer)
    2 205-160 Screw (T80T-4020-F43)
    3 4630 Pinion bearing (inner)
    4 205-423 Gauge Disc
    5 205-159 Gauge Block (2.1993-inch thick) (T80T-4020-F42)
    6 205-D038 Gauge Tube (4.126-inch O.D.) (D81T-4020-F51)
    7 205-226 Aligning Adapter (T85T-4020-AH1)
    8 4010 Rear axle housing
    9 205-111 Handle (T76P-4020-A11)
    5. NOTE: This step duplicates final pinion bearing preload.
  5. Tighten the Handle to achieve the specified rotational torque.
    • Tighten to 2.2 Nm (20 lb-in).
      Fig 5: Checking Differential Pinion Bearing Preload
      G03878601Courtesy of FORD MOTOR CO.
    6. NOTE: The special tool must be offset to obtain an accurate reading.
    Fig 6: Rotating Special Tool
    G03883649Courtesy of FORD MOTOR CO.
  6. Rotate the special tool several half-turns to make sure of correct seating of the pinion bearings, and 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 119 Nm (88 lb-ft).
      Fig 7: Using Special Tool On Differential Side Bearing Caps And Bolts
      G04643937Courtesy 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 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.
  8. 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 8: Identifying Drive Pinion Bearing Adjustment Shim
      G03883651Courtesy of FORD MOTOR CO.
    9. CAUTION: Check the splines on the pinion stem to be sure they are free of burrs. If burrs are evident, remove them by using a fine crocus cloth, working in a rotational motion. Wipe the pinion clean.
    NOTE: The same differential pinion bearing used in the previous procedure must be used in the final assembly of the axle.
    Fig 9: Using Special Tool On Shaft
    G04643939Courtesy of FORD MOTOR CO.
  9. Place the selected shim on the pinion and press the bearing until it is firmly seated on the shaft using the special tools.
  10. Place a new collapsible spacer on the pinion shaft against the pinion stem shoulder.
    Fig 10: Identifying Drive Pinion Collapsible Spacer
    G03878606Courtesy of FORD MOTOR CO.
  11. Install the outer drive pinion bearing and drive pinion shaft oil slinger.
    Fig 11: Identifying Outer Drive Pinion Bearing And Drive Pinion Shaft Oil Slinger
    G03884436Courtesy of FORD MOTOR CO.
  12. Lubricate the new drive pinion seal with grease.
    Fig 12: Installing Drive Pinion Seal
    G03884437Courtesy of FORD MOTOR CO.
  13. Install the drive pinion in the drive pinion carrier bore from inside the rear axle housing. Seat the drive pinion with a plastic hammer.
    Fig 13: Locating Drive Pinion Gear
    G04583053Courtesy of FORD MOTOR CO.
  14. Lubricate the pinion flange splines with grease.
    15. CAUTION: The special tool must be used due to tight spline fit.
    Fig 14: Installing Pinion Flange Using Special Tool
    G03884510Courtesy of FORD MOTOR CO.
  15. With the drive pinion in place in the axle housing, install the pinion flange using the Companion Flange Replacer.
  16. Position the new pinion nut.
    Fig 15: Identifying Pinion Nut
    G03884298Courtesy of FORD MOTOR CO.
    17. 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.
  17. Use the special tool to hold the pinion flange while tightening the pinion nut.
    • Refer to the TORQUE SPECIFICATION  for new pinion bearings in the Specifications portion of this section.
    • Tighten the pinion nut until the desired rotational torque is reached.
      Fig 16: Holding Pinion Flange With Special Tool
      G03883491Courtesy of FORD MOTOR CO.
    18. NOTE: If removed, press the speed sensor ring on with the differential ring gear.
  18. 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.
      Fig 17: Pressing Differential Ring Gear Into Place
      G03884443Courtesy of FORD MOTOR CO.
  19. 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 18: Identifying 12 Differential Ring Gear Bolts
      G03884368Courtesy of FORD MOTOR CO.
  20. Position the differential case in the rear axle housing.
    • Install a shim on the left side as shown in the illustration.
      Fig 19: Identifying Differential Bearing Shim On LH Side
      G03884446Courtesy of FORD MOTOR CO.
    21. CAUTION: The bearing caps must be installed in their original locations and positions.
    NOTE: Apply pressure toward the left side to make sure the left bearing is seated.
    Fig 20: Identifying Bearing Cap/Bolts
    G03884380Courtesy of FORD MOTOR CO.
  21. Install the left bearing cap and loosely install the bearing cap bolts.
  22. Install progressively larger shims on the right side until the largest shim selected can be assembled by hand.
    Fig 21: Locating Progressively Larger Shims
    G04643951Courtesy of FORD MOTOR CO.
  23. Install the right side bearing cap and tighten the 4 bolts.
    • Tighten to 119 Nm (88 lb-ft).
      Fig 22: Identifying Differential Bearing Cap And Differential Bearing Cap Bolts
      G03878679Courtesy of FORD MOTOR CO.
  24. Rotate the differential case to make sure it rotates freely.
    Fig 23: Rotating Differential Case
    G03904430Courtesy of FORD MOTOR CO.
  25. Using the special tool, measure ring gear backlash.
    • If the backlash is within specification, go to Step  31.
    • If a zero backlash condition occurs, go to Step 26.
    • If the backlash is not within specification, go to Step  27.
      Fig 24: Measuring Ring Gear Backlash Using Special Tools
      G03884451Courtesy of FORD MOTOR CO.
  26. If a zero backlash condition occurs, add a 0.50 mm (0.020 inch) shim to the RH side and subtract 0.50 mm (0.020 inch) from the LH side to allow backlash indication. Check backlash. Repeat Step  40.
    27. NOTE: If 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.
  27. To increase or decrease backlash, remove the bearing caps and install a thicker shim and a thinner shim as shown.
    THICKNESS REFERENCE

    Backlash Change Required Thickness Change Required
    mm Inch mm Inch
    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
    • If 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.
      Fig 25: Identifying Differential Bearing Shims
      G03884521Courtesy of FORD MOTOR CO.
  28. Install the bearing caps and bearing cap bolts.
    • Tighten to 119 Nm (88 lb-ft).
      Fig 26: Identifying Differential Bearing Cap And Differential Bearing Cap Bolts
      G03878679Courtesy of FORD MOTOR CO.
  29. Rotate the differential several times to make sure the differential bearings are correctly seated.
    Fig 27: Rotating Differential Case
    G03904430Courtesy of FORD MOTOR CO.
  30. Using the special tool, recheck the backlash.
    Fig 28: Measuring Ring Gear Backlash Using Special Tools
    G03884451Courtesy of FORD MOTOR CO.
  31. Remove the bearing caps and bolts.
    • To establish differential bearing preload, increase both left and right shim sizes by the specification shown in the illustration.
    • Using the special tool, make sure the differential bearing shims are fully seated and the assembly turns freely.
      Fig 29: Installing Differential Bearing Shim Using Special Tool
      G03904436Courtesy of FORD MOTOR CO.
  32. Install the bearing caps and bearing cap bolts.
    • Tighten to 119 Nm (88 lb-ft).
      Fig 30: Identifying Differential Bearing Cap And Differential Bearing Cap Bolts
      G03878679Courtesy of FORD MOTOR CO.
  33. Using the special tool, verify the backlash.
    Fig 31: Measuring Ring Gear Backlash Using Special Tools
    G03884451Courtesy 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 SHAFT .
    37. CAUTION: Make sure the machined surfaces on both the rear axle housing and the differential housing are clean and free of oil before applying the new silicone sealant. The inside of the rear axle must be covered when cleaning the machined surface to prevent contamination.
  37. Clean the gasket mating surface of the rear axle and the differential housing cover.
  38. Apply a new, continuous bead of silicone sealant to the differential housing cover.
    Fig 32: Proper Application Of Sealant To Differential Housing Cover
    G03878622Courtesy of FORD MOTOR CO.
    39. NOTE: The differential housing cover must be installed within 15 minutes of application of the silicone, or new sealant must be applied. If possible, allow one hour before filling with lubricant to ensure the silicone sealant has properly cured.
  39. Install the differential housing cover and the differential housing cover bolts.
    • Tighten to 45 Nm (33 lb-ft).
      Fig 33: Locating Differential Housing Cover Bolts
      G03878623Courtesy of FORD MOTOR CO.
    40. CAUTION: For Traction-Lok® axles, first fill the axle with 118 ml (4 ounces) of friction modifier.
    NOTE: Service refill capacities are determined by filling the axle with the specified lubricant to the specified level below the bottom of the filler hole.
  40. Fill the axle to the level shown with axle lubricant and install the filler plug.
    • Tighten to 30 Nm (22 lb-ft).
      Fig 34: Checking Axle Lubricant Fill Level
      G03884460Courtesy of FORD MOTOR CO.
  41. Position the driveshaft and align the index mark on the pinion flange.
    Fig 35: Identifying Index Marks On Pinion/Driveshaft Flanges
    G03878625Courtesy of FORD MOTOR CO.
    42. 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.
  42. Install the driveshaft flange bolts.
    • Tighten to 103 Nm (76 lb-ft).
      Fig 36: Identifying Driveshaft Flange Bolts
      G03878515Courtesy of FORD MOTOR CO.
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