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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 383 (Rear Drive Axle/Differential 7.5-Inch Ring Gear) >> In-Vehicle Repair >> Drive Pinion >> Installation

Drive Pinion: Installation

WARNING: This page is about a different car, the 2002 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 Respective Bores
    G03434227Courtesy of FORD MOTOR CO.
  2. Tighten the special tool to seat the pinion bearing cups into their bores.
    Fig 2: Tightening Special Tool
    G03434228Courtesy of FORD MOTOR CO.

    Using 205-024, 205-153, & 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
    G03434229Courtesy 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 Using Special Tools
    G03434230Courtesy 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: Inserting Feeler Gauge Between Cup & Bottom Of Its Bore
    G03434231Courtesy 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
    G03434232Courtesy of FORD MOTOR CO.
  6. Assemble and position the special tools.
    7. NOTE: This step duplicates final pinion bearing preload.
  7. Tighten the special tool to the specification.
    8. Fig 7: Tightening Special Tool
    G03434233Courtesy of FORD MOTOR CO.
    NOTE: The special tool must be offset to obtain an accurate reading.
    Fig 8: Rotating Special Tool
    G03434234Courtesy 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, Differential Side Bearing Caps & Bolts
    G03434235Courtesy 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: Using drive pinion bearing Adjusting Shim As A Gauge
    G03434236Courtesy 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 tools.
  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 On Pinion & Pinion Shim
    G03434237Courtesy of FORD MOTOR CO.
  12. Place a new drive pinion collapsible spacer on the pinion shaft against the pinion stem shoulder.
    Fig 12: Installing Drive Pinion Collapsible Spacer
    G03434238Courtesy 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.
    Fig 13: Installing Rear Axle Drive Pinion Seal
    G03434239Courtesy of FORD MOTOR CO.
  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.
    14. NOTE: Coat the lips of the rear axle drive pinion seal with grease.
    Fig 14: Installing Rear Axle Drive Pinion Seal
    G03434240Courtesy 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
    G03434241Courtesy 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
    G03434242Courtesy 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
    G03434243Courtesy of FORD MOTOR CO.
  19. Position the new pinion nut.
    Fig 18: Installing Pinion Nut
    G03434244Courtesy 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.
    Fig 19: Tightening Pinion Nut While Holding Pinion Flange
    G03434245Courtesy of FORD MOTOR CO.
  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  .
  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: Aligning Driveshaft To Pinion Flange
    G03434246Courtesy 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: Tightening Driveshaft Bolts
    G03434247Courtesy of FORD MOTOR CO.
  24. Install the driveshaft bolts.
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