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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 282 (Rear Drive Axle/Differential - Ford 7.5-Inch Ring Gear) >> In-Vehicle Repair >> Drive Pinion >> Installation

Drive Pinion: Installation

WARNING: This page is about a different car, the 2003 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.

Using 205-024 

  1. Position the special tools and the inner and outer bearing cups in their respective bores.
    1. After placing the inner and outer 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.
      Fig 1: Positioning Special Tools & Inner & Outer Bearing Cups In Their Respective Bores
      G01291313Courtesy of FORD MOTOR CO.
  2. Tighten the special tool to seat the pinion bearing cups into their bores.
    Fig 2: Seating Pinion Bearing Cups Into Their Bores
    G01291314Courtesy of FORD MOTOR CO.

    Using 205-024, 205-153, and 205-D055 

  3. Using the special tools, drive the outer pinion bearing cup into the axle housing.
    Fig 3: Driving Outer Pinion Bearing Cup Into Axle Housing
    G01291315Courtesy of FORD MOTOR CO.
  4. Using the special tools, drive the inner pinion bearing cup into the axle housing.
    Fig 4: Driving Inner Pinion Bearing Cup Into Axle Housing
    G01291316Courtesy of FORD MOTOR CO.

    Setting pinion depth 

    5. CAUTION: Whenever new cups are installed, new pinion bearings must also be installed.
    NOTE: If a feeler gauge 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 5: Making Sure Cups Are Correctly Seated In Their Bores
    G01291317Courtesy of FORD MOTOR CO.
  5. Make sure the cups are correctly seated in their bores.
    6. NOTE: Apply only a light oil film on the pinion bearings before assembling the tool.
    Fig 6: Assembling & Positioning Special Tools
    G01291318Courtesy of FORD MOTOR CO.
  6. Assemble and position the special tools.
    7. NOTE: This step duplicates final pinion bearing preload.
    Fig 7: Tightening Special Tool
    G01291319Courtesy of FORD MOTOR CO.
  7. Tighten the special tool to the specification.
    8. NOTE: The special tool must be offset to obtain an accurate reading.
    Fig 8: Rotating Special Tool Several Half-Turns To Ensure Correct Seating Of Pinion Bearings
    G01291320Courtesy of FORD MOTOR CO.
  8. Rotate the special tool several half-turns to ensure correct seating of the pinion bearings and position the special tool.
  9. Install the special tool.
    1. Position the special tool.
    2. Install the differential side bearing caps.
    3. Install the four differential side bearing cap bolts.
      Fig 9: Installing Special Tool
      G01291321Courtesy of FORD MOTOR CO.
    10. 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 final assembly of integral rear axle assemblies.
  10. 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 10: Using Drive Pinion Bearing Adjustment Shim As Gauge For Shim Selection
      G01291322Courtesy of FORD MOTOR CO.
  11. Using the special tool, press the pinion bearing until it is firmly seated on the pinion and pinion shim.
    Fig 11: Pressing Pinion Bearing Until It Is Firmly Seated On Pinion & Pinion Shim
    G01291323Courtesy of FORD MOTOR CO.
  12. Place a new drive pinion collapsible spacer on the pinion shaft against the pinion stem shoulder.
    Fig 12: Placing Drive Pinion Collapsible Spacer On Pinion Shaft Against Pinion Stem Shoulder
    G01291324Courtesy of FORD MOTOR CO.
    13. CAUTION: Installation without the correct tool can result in early seal failure. If the rear axle drive pinion seal becomes cocked during installation, remove it and install a new one.
  13. Install a new rear axle drive pinion seal.
    1. Install the outer pinion bearing.
    2. Install the rear axle drive pinion shaft oil slinger in the rear axle housing.
    3. Install the rear axle drive pinion seal on the special tool.
      Fig 13: Installing Rear Axle Drive Pinion Seal
      G01291325Courtesy of FORD MOTOR CO.
    14. NOTE: Coat the lips of the rear axle drive pinion seal with grease.
    Fig 14: Driving Rear Axle Drive Pinion Seal Into Place
    G01291326Courtesy of FORD MOTOR CO.
  14. Place the special tool in the pinion seal bore and drive the rear axle drive pinion seal into place.
  15. From inside the rear axle housing, install the drive pinion assembly into the rear axle housing bore.
    Fig 15: Installing Drive Pinion Assembly Into Rear Axle Housing Bore
    G01291327Courtesy of FORD MOTOR CO.
  16. Lubricate the pinion flange splines with lubricant.
    17. NOTE: Disregard the scribe marks if a new pinion flange is being installed.
    Fig 16: Aligning Pinion Flange With Drive Pinion Shaft
    G01291328Courtesy of FORD MOTOR CO.
  17. Align the pinion flange with the drive pinion shaft.
  18. With the drive pinion in place in the rear axle housing, install the pinion flange using the special tool.
    Fig 17: Installing Pinion Flange Using Special Tool
    G01291329Courtesy of FORD MOTOR CO.
  19. Position the new pinion nut.
    Fig 18: Positioning Pinion Nut
    G01291330Courtesy of FORD MOTOR CO.
    20. CAUTION: Under no circumstances is the pinion nut to be backed off to reduce preloads. If reduced preload is required, a new collapsible spacer and pinion nut must be installed.
    CAUTION: Remove the special tool while taking preload readings with the Nm (inch-pound) torque wrench.
  20. Using the special tool, hold the pinion flange and tighten the pinion nut.
    • Rotate the pinion occasionally to make sure the cone and roller bearings are seating correctly.
    • Install a Nm (inch-pound) torque wrench on the pinion nut.
    • Rotating the pinion through several revolutions, take frequent cone and roller bearing torque preload readings until the original recorded preload reading is obtained.
    • If the original recorded preload is lower than specifications, tighten to the appropriate specifications for used bearings. If the preload is higher than specification, tighten the nut to the original reading as recorded. For additional information, refer to TORQUE SPECIFICATIONS .
      Fig 19: Holding Pinion Flange & Tightening Pinion Nut
      G01291331Courtesy of FORD MOTOR CO.
  21. Install differential case in the rear axle housing. For additional information, refer to DIFFERENTIAL CASE .
  22. Install the axle shafts. For additional information, refer to AXLE SHAFT .
  23. Position the driveshaft and align the marks on the pinion flange.
    Fig 20: Positioning Driveshaft & Aligning Marks On Pinion Flange
    G01291332Courtesy of FORD MOTOR CO.
    24. CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion flange pilot. To make sure that the yoke seats squarely on the flange, tighten the bolts evenly in a cross pattern as shown.
    Fig 21: Installing Driveshaft Bolts
    G01291333Courtesy of FORD MOTOR CO.
  24. Install the driveshaft bolts.
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