Differential Ring And Pinion: Installation

WARNING: This page is about a different car, the 2007 Ford Pickup and 2007 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Special Tools Assembly

Courtesy of FORD MOTOR CO.

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 2: Installing Pinion Bearing Cups

Courtesy of FORD MOTOR CO.

Tighten the special tool to seat the pinion bearing cups into their bores.

Fig 3: Checking Clearance Between Cup And Bore

Courtesy of FORD MOTOR CO.

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.

Check that the pinion bearing cups have seated correctly in their bores.

Fig 4: 2 Bolts In Differential Case Flange, Anti-Lock Sensor Ring & Differential Ring Gear

Courtesy of FORD MOTOR CO.

NOTE: Apply Threadlock and Sealer to the 2 new differential ring gear bolts.

NOTE: If removed, install the anti-lock speed sensor ring.

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.

Fig 5: Pressing Anti-Lock Speed Sensor Ring

Courtesy of FORD MOTOR CO.

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 6: Identifying Ring Gear Bolts

Courtesy of FORD MOTOR CO.

Apply Threadlock and Sealer and install the 10 remaining bolts alternately and evenly.
- Tighten to 298 Nm (220 lb-ft).

Fig 7: Outboard Spacers

Courtesy of FORD MOTOR CO.

Install the original outboard spacers in the side from which they were removed.

Fig 8: Differential Assembly & Special Tools In Differential Housing

Courtesy of FORD MOTOR CO.

NOTE: Remove all nicks, burrs and dirt from the differential carrier hubs to allow the differential bearings to rotate freely.

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.

Fig 9: Installing Special Tools

Courtesy of FORD MOTOR CO.

NOTE: Use a dial indicator with a minimum travel capability of 5.08 mm (0.200 in).

Mount the special tools as shown. Locate the tip of special tool on the flat surface of one of the differential ring gear bolts.

Fig 10: Zeroing Dial Indicator

Courtesy of FORD MOTOR CO.

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.

Force the differential carrier as far as possible toward the indicator. With force still applied, zero the indicator.

Fig 11: Checking Backlash

Courtesy of FORD MOTOR CO.

Force the differential carrier as far as it will go in the opposite direction. Record the total differential carrier end play reading.
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.

Fig 12: Special Tools Assembly With Bearings

Courtesy of FORD MOTOR CO.

NOTE: 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.

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.
Thread on the special tool.

Fig 13: Special Tool & Caps

Courtesy of FORD MOTOR CO.

Install the special tool.
1. Install the differential bearing caps.
2. Install the differential bearing cap bolts.
- Tighten to 108 Nm (80 lb-ft).

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

Fig 14: Identifying Drive Pinion Bearing Adjustment Shim

Courtesy of FORD MOTOR CO.

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.

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.
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.

Fig 15: Installing Pinion Bearing

Courtesy of FORD MOTOR CO.

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.

Using the special tools and a suitable press, install the pinion bearing.
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.
Install the outer pinion bearing and drive pinion oil slinger.

Fig 16: Installing Pinion Flange

Courtesy of FORD MOTOR CO.

CAUTION: The pinion flange must never be hammered on or installed with power tools or damage to the component may occur.

Using the special tool, install the pinion flange.

Fig 17: Holding Pinion Flange With Special Tool

Courtesy of FORD MOTOR CO.

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 18: Checking Pinion Rotational Torque

Courtesy of FORD MOTOR CO.

Using a Nm (lb-in) torque wrench, rotate the pinion. The rotational torque must read 2.3-4.5 Nm (20-40 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 19: Holding Pinion Flange With Special Tool

Courtesy of FORD MOTOR CO.

While using a suitable tool to prevent the pinion flange from turning, remove and discard the old washer and pinion nut.

Fig 20: Removing Pinion Flange Using Special Tool

Courtesy of FORD MOTOR CO.

Using the special tool, remove the pinion flange.

Fig 21: Driving Pinion Seal Into Housing Using Special Tool

Courtesy of FORD MOTOR CO.

NOTE: 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.

Using a suitable tool, drive the pinion seal into the housing.
- Coat the pinion seal (rubber lips) with axle lubricant.

Fig 22: Checking Pinion Rotational Torque

Courtesy of FORD MOTOR CO.

NOTE: The pinion flange must never be hammered on or installed with power tools.

Using the special tool, install the pinion flange.

Fig 23: Holding Pinion Flange With Special Tool

Courtesy of FORD MOTOR CO.

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 24: Checking Pinion Rotational Torque

Courtesy of FORD MOTOR CO.

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 25: Installing Special Tools

Courtesy of FORD MOTOR CO.

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 26: Zeroing Dial Indicator

Courtesy of FORD MOTOR CO.

Force the differential case away from the drive pinion. With force still applied, set the indicator to zero.

Fig 27: Checking Backlash

Courtesy of FORD MOTOR CO.

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.

Force the differential ring gear into mesh with the pinion to obtain the indicator reading. Record the reading.

Fig 28: Differential Assembly & Special Tools In Differential Housing

Courtesy of FORD MOTOR CO.

Remove the differential case from the differential housing.
Remove the master bearings from the differential case.
- Make sure the inner bearing shims remain on the differential carrier hubs.

Fig 29: Identifying Special Tool For Differential Bearing Installation

Courtesy of FORD MOTOR CO.

Using the special tool, install the differential bearing and shim on the LH side of the differential case.

Fig 30: Using Special Tools To Install Differential Bearing Onto Hub

Courtesy of FORD MOTOR CO.

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.
Assemble the differential bearing cups to the differential bearings.
Place one outboard spacer of the necessary thickness, as determined from the previous measurement, on the LH side of the differential housing.
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.

Fig 31: Using Special Tool To Spread Differential Housing

Courtesy of FORD MOTOR CO.

CAUTION: Do not spread the differential housing more than specified or damage to the housing may occur.

NOTE: Avoid nicking the ring gear teeth and the anti-lock speed sensor ring during assembly.

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 32: Locating Differential Bearing Caps

Courtesy of FORD MOTOR CO.

NOTE: Match the mating letters as noted during disassembly.

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 33: Checking Pinion Rotational Torque

Courtesy of FORD MOTOR CO.

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 34: Measuring Differential Ring Gear & Pinion Backlash Using Special Tools

Courtesy of FORD MOTOR CO.

Using the special tools, measure the differential ring gear and pinion backlash at 3 equally spaced points.
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.
Install the axle shafts. For additional information, refer to WHEEL HUBS AND BEARINGS - FULL FLOATING AXLE - DANA article.

Fig 35: Marking Driveshaft Flange And Pinion Flange

Courtesy of FORD MOTOR CO.

NOTE: Align the index marks made during removal.

Connect the driveshaft flange and the axle flange and install the 4 bolts.
- Tighten to 100 Nm (74 lb-ft).

Fig 36: Proper Application Of Sealant To Differential Housing Cover

Courtesy of FORD MOTOR CO.

NOTE: Install the differential cover within 15 minutes of applying the silicone or it will be necessary to remove and reapply new sealant.

Apply a continuous bead of sealant of the specified thickness to the differential housing cover.
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.
Install the 8 remaining bolts. Tighten the bolts alternately and evenly.
- Tighten to 45 Nm (33 lb-ft).
- If possible, allow an hour cure time before filling the axle with the correct amount of specified lubricant.
Fill the axle with the specified type and amount of fluid.