Drive Pinion: Installation

Using Special Tool 205-024 

1. Position the special tools and the inner and outer pinion bearing cups in their respective bores.
   1. After placing the inner and outer bearing cups in their bores, place the special tool on the inner bearing cup.
   2. Place the special tool on the outer bearing cup.
   3. Install the special tool.
   Fig 1: Positioning Special Tools, Inner & Outer Pinion Bearing Cups In Respective Bores

   Courtesy of FORD MOTOR CO.
2. Tighten the special tool to seat the pinion bearing cups in their bores.
   Fig 2: Tightening Special Tool

   Courtesy of FORD MOTOR CO.
CAUTION: Always install new pinion bearings when installing new pinion bearing cups.
NOTE: If the feeler gauge can fit between a cup and the bottom of its bore at any point around the cup, remove and reseat the cup.
Fig 3: Fitting Feeler Gauge Between Cup & Bottom Of Bore
Courtesy of FORD MOTOR CO.
3. Check that the cups have seated correctly in their bores.
4. Using the special tools, drive the outer pinion bearing cup into the differential housing.
   Fig 4: Installing Drive Pinion Bearing Cup

   Courtesy of FORD MOTOR CO.

   Using Special Tools 205-153, 205-024, And 205 -D055 

   NOTE: This is an alternate method for installing the pinion bearing cups. Carry out this procedure if pinion bearing cup installation was not done in the previous steps.
5. Using the special tools, drive the inner pinion bearing cup into the differential housing.
   Fig 5: Installing Inner Rear Axle Pinion Bearing Cup

   Courtesy of FORD MOTOR CO.
CAUTION: Always install new pinion bearings when installing new pinion bearing cups.
NOTE: If the feeler gauge can fit between a cup and the bottom of its bore at any point around the cup, remove and reseat the cup.
Fig 6: Fitting Feeler Gauge Between Cup & Bottom Of Bore
Courtesy of FORD MOTOR CO.
6. Check that the cups have seated correctly in their bores.

   Setting Pinion Depth 

NOTE: Apply only a light oil film on the pinion bearings before assembling the tool.
Fig 7: Positioning Special Tool In Differential Housing
Courtesy of FORD MOTOR CO.
7. Assemble and position the following in the differential housing.
NOTE: This step duplicates final pinion bearing preload.
Fig 8: Tightening Special Tool
Courtesy of FORD MOTOR CO.
8. Tighten the special tool to the specification shown.
NOTE: Offset the special tool to obtain an accurate reading.
Fig 9: Rotating Special Tool
Courtesy of FORD MOTOR CO.
9. Rotate the special tool several half-turns to make sure the pinion bearings seat correctly and position the special tool as shown.
10. Install the special tool.
    1. Position the special tool.
    2. Install the bearing caps.
    3. Install the bolts.
    Fig 10: Installing Special Tool

    Courtesy of FORD MOTOR CO.
CAUTION: Use only flat, clean drive pinion bearing adjustment shims.
CAUTION: Selection of too thick a shim results in a deep tooth contact at final assembly. Do not attempt to force the shim between the special tools. A slight drag indicates correct shim selection.
Fig 11: Using A Drive Pinion Bearing Adjustment Shim As A Gauge
Courtesy of FORD MOTOR CO.
11. Use a drive pinion bearing adjustment shim as a gauge for shim selection.
    • After determining the correct shim thickness, remove the special tools.
12. Position the correct thickness drive pinion bearing adjustment shim and the pinion bearing on the drive pinion. Using a suitable press and the special tools, press the pinion bearing until it seats firmly on the pinion.
    Fig 12: Installing Pinion Bearing On Pinion

    Courtesy of FORD MOTOR CO.
13. Place a new drive pinion collapsible spacer on the pinion shaft against the pinion stem shoulder.
    Fig 13: Installing Drive Pinion Collapsible Spacer

    Courtesy of FORD MOTOR CO.
CAUTION: Installation without the correct tool can result in early seal failure.
Fig 14: Installing Rear Axle Drive Pinion Seal
Courtesy of FORD MOTOR CO.
14. Install a new rear axle drive pinion seal.
    1. Install the front pinion bearing.
    2. Install the rear axle drive pinion shaft oil slinger.
    3. Install the rear axle drive pinion seal on the special tool.
CAUTION: If the rear axle drive pinion seal becomes misaligned during installation, remove the seal and install a new seal.
NOTE: Coat the rear axle drive pinion seal lips with grease.
Fig 15: Installing Rear Axle Drive Pinion Seal
Courtesy of FORD MOTOR CO.
15. Position the rear axle drive pinion seal in the seal bore, and use the special tool to drive the seal into place.
16. From inside the differential housing, install the drive pinion assembly (drive pinion, shims, bearing, and the collapsible spacer) into the carrier bore.
    Fig 16: Installing Drive Pinion Assembly Into Carrier Bore

    Courtesy of FORD MOTOR CO.
17. Lubricate the pinion flange splines with rear axle lubricant.
NOTE: Disregard the index marks if installing a new pinion flange.
Fig 17: Positioning Pinion Flange
Courtesy of FORD MOTOR CO.
18. Position the pinion flange.
19. Using the special tool, install the pinion flange.
    Fig 18: Installing Pinion Flange

    Courtesy of FORD MOTOR CO.
20. Position the new nut.
    Fig 19: Positioning Pinion Flange Nut

    Courtesy of FORD MOTOR CO.
CAUTION: Do not under any circumstance loosen the nut to reduce preload. If it is necessary to reduce preload, install a new collapsible spacer and nut.
CAUTION: Remove the special tool while taking preload readings with the Nm (inch-pound) torque wrench.
Fig 20: Tightening Nut Using Special Tool To Hold Pinion Flange
Courtesy of FORD MOTOR CO.
21. Use the special tool to hold the pinion flange while tightening the nut.
    • Rotate the pinion occasionally to make sure the pinion bearings seat correctly. Take frequent pinion bearing preload readings by rotating the pinion with a Nm (inch-pound) torque wrench.
    • For new pinion bearings, tighten the nut to specification. Refer to TORQUE SPECIFICATIONS  for new pinion bearings in the Specifications portion of this section.
    • For used pinion bearings, if the preload recorded prior to disassembly is lower than the specification for used bearings, then tighten the nut to specification. Refer to TORQUE SPECIFICATIONS  for used pinion bearings.
    • For used pinion bearings, if the preload recorded prior to disassembly is higher than the specification for used bearings, then tighten the nut to the original reading as recorded.

    Final Assembly 

22. Install the differential case in the differential housing. For additional information, refer to DIFFERENTIAL CASE .
23. Position the driveshaft flange on the pinion flange with the index marks aligned.
    Fig 21: Positioning Driveshaft Flange On Pinion Flange

    Courtesy of FORD MOTOR CO.
CAUTION: If new bolts to retain the driveshaft to the axle are not available, coat the threads of the original bolts with threadlock.
CAUTION: The driveshaft flange fits tightly on the rear axle pinion flange pilot. To mark sure that the driveshaft flange seats squarely on the pinion flange, tighten the bolts evenly in a cross pattern as shown.
Fig 22: Installing Driveshaft Flange Bolts
Courtesy of FORD MOTOR CO.
24. Install the bolts.