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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1800 (Rear Drive Axle/Differential - Ford 9.75-Inch Ring Gear -- F150 & Mark LT) >> In-Vehicle Servicing >> Differential Bearings >> Installation

Differential Bearings: Installation

WARNING: This page is about a different car, the 2007 Lincoln Mark LT and 2007 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. Place the special tool on the outer drive pinion bearing cup.
    2. Place the special tool on the inner drive pinion bearing cup.
    3. Install the special tool.
    2. Fig 1: Identifying Special Tool On Inner And Outer Drive Pinion Bearing Cup
    GF0003139Courtesy of FORD MOTOR CO.
  2. Tighten the special tool to seat the 2 drive pinion bearing cups into their bores.
    3. Fig 2: Identifying Special Tool To Drive Pinion Bearing
    GF0003140Courtesy of FORD MOTOR CO.
    NOTE: 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.
  3. Make sure the 2 drive pinion bearing cups are correctly seated in their bores.
    4. Fig 3: Checking Clearance Between Cup And Bore
    G03878664Courtesy of FORD MOTOR CO.
    NOTE: Use the same drive pinion bearings and the drive pinion bearing adjustment shim from the drive pinion bearing adjustment shim selection procedure for final assembly.
    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 Special Tools On Drive Pinion Bearings
    GF0003141Courtesy of FORD MOTOR CO.
    Item Part Number Description
    1 4621 Outer pinion bearing
    2 205-160 Adapter for 205-S127
    3 4630 Inner pinion bearing
    4 205-383 Depth Gauge/Aligner, Drive Pinion
    5 205-159 Adapter for 205-S127
    6 205-377 Drive Pinion Gauge Tube
    7 205-226 Depth Gauge/Aligner, Drive Pinion
    8 4010 Rear axle housing outer (front) pinion bearing
    9 205-111 Adapter for 205-S127
  4. Install the new drive pinion bearings and special tools as shown.
  5. Tighten the special tool to the specified rotational torque.
    • Tighten to 2.2 Nm (20 lb-in).
    6. Fig 5: Checking Differential Pinion Bearing Preload
    G03878601Courtesy of FORD MOTOR CO.
    NOTE: The gauge block must be offset to obtain an accurate reading.
  6. Rotate the gauge block several half turns to make sure of correct seating of the drive pinion bearings and position the gauge block.
    7. Fig 6: Rotating Special Tool
    G03883649Courtesy of FORD MOTOR CO.
  7. Install the special tool.
    • Position the special tool.
    • Install the 2 differential bearing caps.
    • Install the 4 differential bearing cap bolts.
      • Tighten to 105 Nm (77 lb-ft).
    8. Fig 7: Identifying Differential Bearing Cap Bolts
    GF0003142Courtesy of FORD MOTOR CO.
    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 gauge block and gauge tube. This will minimize selection of a drive pinion bearing adjustment shim thicker than required, which results in a deep tooth contact in final assembly of integral axle assemblies.
  8. Use a drive pinion bearing adjustment shim as a gauge for drive pinion bearing adjustment shim selection.
    • The pinion bearing adjustment shim is checked between the gauge block and the gauge tube.
    9. Fig 8: Identifying Drive Pinion Bearing Adjustment Shim
    GF0003085Courtesy of FORD MOTOR CO.
  9. Remove the pinion depth gauge set from the axle housing.
  10. Using the special tools, press the drive pinion bearing and selected drive pinion bearing adjustment shim until they are firmly seated on the pinion gear.
    11. Fig 9: Identifying Special Tools On Drive Pinion Bearing
    GF0003143Courtesy of FORD MOTOR CO.
  11. Place a new drive pinion collapsible spacer on the pinion gear against the pinion gear shoulder.
    12. Fig 10: Identifying Drive Pinion Collapsible Spacer
    GF0000836Courtesy of FORD MOTOR CO.
  12. Install the outer drive pinion bearing and drive pinion shaft oil slinger.
    13. Fig 11: Identifying Outer Drive Pinion Bearing And Drive Pinion Shaft Oil Slinger
    GF0000839Courtesy of FORD MOTOR CO.
  13. Lubricate the new drive pinion seal with grease.
  14. Using the special tool, install a new drive pinion seal.
    15. Fig 12: Installing Drive Pinion Seal
    G03884437Courtesy of FORD MOTOR CO.
  15. Lubricate the pinion flange splines with grease.
  16. Install the pinion gear in the pinion gear bore from inside the axle housing.
    17. Fig 13: Locating Drive Pinion Gear
    GF0000840Courtesy of FORD MOTOR CO.
  17. Using the special tool, install the pinion flange.
    18. Fig 14: Installing Pinion Flange Using Special Tool
    G03884510Courtesy of FORD MOTOR CO.
  18. Position the new pinion nut.
    19. Fig 15: Identifying Pinion Nut
    GF0003128Courtesy of FORD MOTOR CO.
    NOTE: 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.
    NOTE: Remove the special tool while taking drive pinion bearing preload readings with the Nm (lb-in) torque wrench.
  19. 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 drive pinion bearing preload specification is obtained.
    20. Fig 16: Holding Pinion Flange With Special Tool
    G03883491Courtesy of FORD MOTOR CO.
  20. Press the LH and RH differential bearing on the differential assembly.
    21. Fig 17: Pressing Differential Bearings On Differential Case Using Special Tool
    G03884442Courtesy of FORD MOTOR CO.
  21. Install the differential assembly in the axle housing.
    22. Fig 18: View Of Differential Assembly In Axle Housing
    GF0000841Courtesy of FORD MOTOR CO.
    NOTE: Install the differential bearing shims with the chamfer facing outboard.
  22. Install a differential bearing shim on the LH side.
    23. Fig 19: Identifying Differential Bearing Shim On LH Side
    G03884446Courtesy of FORD MOTOR CO.
    NOTE: 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.
  23. Install the LH differential bearing cap and loosely install the 2 differential bearing cap bolts.
    24. Fig 20: Identifying LH Differential Bearing Cap And Bolts
    GF0000842Courtesy of FORD MOTOR CO.
    NOTE: Install the differential bearing shims with the chamfer facing outboard.
  24. Install progressively larger differential bearing shims on the RH side until the largest differential bearing shim selected that can be installed by hand.
    25. Fig 21: Identifying Differential Bearing Shim
    GF0000843Courtesy 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).
    26. Fig 22: Identifying Differential Bearing Cap And Differential Bearing Cap Bolts
    G03878679Courtesy of FORD MOTOR CO.
  26. Rotate the differential assembly to make sure it rotates freely.
    27. Fig 23: Rotating Differential Assembly
    GF0000844Courtesy of FORD MOTOR CO.
    NOTE: If ring gear backlash is within specification, go to Step 31.
  27. Using the special tools, measure ring gear backlash.
    28. Fig 24: Measuring Ring Gear Backlash Using Special Tools
    G03884451Courtesy of FORD MOTOR CO.
    NOTE: Install the differential bearing shims with the chamfer facing outboard.
    NOTE: The differential bearing caps must be removed before differential bearing shims can be installed.
  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 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. Fig 25: Identifying Differential Bearing Shims
    G03884521Courtesy of FORD MOTOR CO.
  29. Rotate the differential assembly several times to make sure the differential bearings are seated.
    30. Fig 26: Rotating Differential Assembly
    GF0000870Courtesy of FORD MOTOR CO.
  30. Using the special tools, recheck the ring gear backlash.
    31. Fig 27: Measuring Ring Gear Backlash Using Special Tools
    G03884451Courtesy of FORD MOTOR CO.
  31. Remove the 4 differential bearing cap bolts and 2 differential bearing caps.
    32. Fig 28: Locating Differential Bearing Cap Bolts
    GF0003144Courtesy of FORD MOTOR CO.
    NOTE: Install the differential bearing shims with the chamfer facing outboard.
    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.
  32. Using the special tool, install the 2 differential bearing shims.
    33. Fig 29: Identifying Special Tool To Differential Bearing Shims
    GF0003145Courtesy of FORD MOTOR CO.
  33. Install the 2 differential bearing caps and 4 differential bearing cap bolts.
    • Tighten to 105 Nm (77 lb-ft).
    34. Fig 30: Identifying Differential Bearing Cap And Differential Bearing Cap Bolts
    G03878679Courtesy of FORD MOTOR CO.
  34. Apply high contrast hypoid gear 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  in this article.
    37. NOTE: Make sure the machined surfaces on both the axle housing and the differential housing cover are clean and free of oil before applying the new silicone sealant. The inside of the axle must be covered when cleaning the machined surface to prevent contamination.
  37. Clean the gasket mating surface of the axle and the differential housing cover.
  38. Apply a new, continuous bead of sealant to the differential housing cover.
    39. Fig 31: Proper Application Of Sealant To Differential Housing Cover
    GF0003119Courtesy of FORD MOTOR CO.
    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 12 differential housing cover bolts.
    • Tighten to 45 Nm (33 lb-ft).
    40. Fig 32: Locating Differential Housing Cover Bolts
    G03878623Courtesy of FORD MOTOR CO.
    NOTE: For Traction-Lok® axles, first fill the axle with 118 ml (4 oz) 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. Remove the fill plug, fill the axle to the level shown with axle lubricant and install the filler plug.
    • Tighten to 30 Nm (22 lb-ft).
    41. Fig 33: Checking Axle Lubricant Fill Level
    G03884460Courtesy of FORD MOTOR CO.
  41. Position the driveshaft and align the index mark on the pinion flange.
    42. Fig 34: Identifying Index Marks On Pinion/Driveshaft Flanges
    GF0000845Courtesy of FORD MOTOR CO.
    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 4 driveshaft flange bolts.
    • Tighten to 103 Nm (76 lb-ft).
    43. Fig 35: Identifying Driveshaft Flange Bolts
    GF0000834Courtesy of FORD MOTOR CO.
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