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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 315 (Drive Axle/Differential - 8.8-Inch Ring Gear) >> In-Vehicle Repair >> Drive Pinion >> Installation

Drive Pinion: Installation

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    NOTE: This step and the following step show the preferred method for installing the pinion bearing cups. An alternate method is shown following these two steps.
  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: Placing The Special Tool (Outer) On The Outer Pinion Bearing Cup
      G01440446Courtesy of FORD MOTOR CO.
  2. Tighten the special tool to seat the pinion bearing cups into their bores.
    Fig 2: Installing Pinion Bearing Cups Into Their Bores
    G01440447Courtesy of FORD MOTOR CO.
    3. NOTE: This step and the following step are alternate methods for installing the pinion bearing cups. Carry out these two steps if pinion bearing cup installation was not done in the previous steps.
    Fig 3: Installing Outer Pinion Bearing Cup Into Rear Axle Housing
    G01440448Courtesy of FORD MOTOR CO.
  3. Using the special tools, drive the outer pinion bearing cup into the rear axle housing.
  4. Using the special tools, drive the inner pinion bearing cup into the axle housing.
    Fig 4: Installing Inner Pinion Bearing Cup Into Axle Housing
    G01440449Courtesy of FORD MOTOR CO.
    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: Inserting Feeler Gauge Between Cup And Bottom Of Bore
    G01440450Courtesy 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: Positioning Special Tools
    G01440451Courtesy of FORD MOTOR CO.
  6. Assemble and position the special tools.
    7. NOTE: This step duplicates final pinion bearing preload.
    Fig 7: Checking Pinion Bearing Preload
    G01440452Courtesy of FORD MOTOR CO.
  7. Tighten the special tool to the specification shown.
    8. NOTE: The special tool must be offset to obtain an accurate reading.
    Fig 8: Positioning Special Tool
    G01440453Courtesy of FORD MOTOR CO.
  8. Rotate the special tool several half-turns to make sure of 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 Differential Side Bearing Cap Bolts
    G01440454Courtesy 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
    Fig 10: Identifying Drive Pinion Bearing Adjustment Shim Position
    G01440455Courtesy of FORD MOTOR CO.
  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 tool.
  11. Using the special tools, press the pinion bearing and pinion shim until seated firmly on the pinion.
    Fig 11: Installing Pinion Bearing
    G01440456Courtesy of FORD MOTOR CO.
  12. Place a new drive pinion collapsible spacer (4662) on the pinion shaft against the pinion stem shoulder.
    Fig 12: Placing Drive Pinion Collapsible Spacer On Pinion Shaft
    G01440457Courtesy 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 front pinion bearing cone and roller.
    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
      G01440458Courtesy of FORD MOTOR CO.
    14. NOTE: Coat the lips of the rear axle drive pinion seal with Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.
    Fig 14: Installing Rear Axle Drive Pinion Seal
    G01440459Courtesy of FORD MOTOR CO.
  14. Place the special tool in the rear axle drive pinion seal bore, and drive the rear axle drive pinion seal into place.
  15. From inside the rear axle housing (4010), install the drive pinion assembly (drive pinion, shims, rear bearing cone and roller, and drive pinion collapsible spacer) into the rear axle bore.
    Fig 15: Installing Drive Pinion Assembly
    G01440460Courtesy of FORD MOTOR CO.
  16. Lubricate the pinion flange splines.
    • Use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.
    17. NOTE: Disregard the scribe marks if a new pinion flange is being installed.
    Fig 16: Aligning Pinion Flange With Drive Pinion Shaft
    G01440461Courtesy 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
    G01440462Courtesy of FORD MOTOR CO.
  19. Position the new pinion nut.
    Fig 18: Positioning Pinion Nut
    G01440463Courtesy of FORD MOTOR CO.
    20. 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.
    Fig 19: Tightening Pinion Nut
    G01440464Courtesy of FORD MOTOR CO.
  20. Using the special tool to hold the pinion flange, 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 DIFFERENTIAL CASE .
  21. Position the rear driveshaft and align the marks on the pinion flange.
    Fig 20: Positioning Rear Driveshaft And Align Marks On Pinion Flange
    G01440465Courtesy of FORD MOTOR CO.
    22. 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: Tightening Rear Driveshaft Bolts
    G01440466Courtesy of FORD MOTOR CO.
  22. Install the bolts and tighten to specification.
  23. Install the differential case in the rear axle differential. For additional information, refer to DIFFERENTIAL CASE .
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