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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 640 (Rear Drive Axle/Differential - DANA 80 -- F350 Super Duty) >> In-Vehicle Repair >> Differential Ring and Pinion >> Installation

Differential Ring and Pinion: Installation

WARNING: This page is about a different car, the 2004 Ford Pickup and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. 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.
      Fig 1: Installing Special Tool
      G02768774Courtesy of FORD MOTOR CO.
  2. Tighten the special tool to seat the pinion bearing cups into their bores.
    Fig 2: Tightening Pinion Bearing Cups Into Bores Using Special Tool
    G02768775Courtesy of FORD MOTOR CO.
    3. 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.
    Fig 3: Checking Pinion Bearing Cups
    G02768776Courtesy of FORD MOTOR CO.
  3. Check that the pinion bearing cups have seated correctly in their bores.
    4. NOTE: Apply Threadlock and Sealer TA-25 or equivalent meeting Ford specification WSK-M2G351 -A5 to the new differential ring gear bolts.
    Fig 4: Installing Anti-Lock Speed Sensor Ring
    G02768777Courtesy of FORD MOTOR CO.
  4. If removed, install the anti-lock speed sensor ring.
  5. 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 5: Pressing Anti-Lock Speed Sensor Ring And Differential Ring Gear On Differential Carrier
    G02768778Courtesy of FORD MOTOR CO.
  6. Apply threadlock and install the grade 9 differential ring gear bolts alternately and evenly.
    • Tighten to 298 Nm (220 lb-ft).
    • Use Threadlock and Sealer TA-25 or equivalent meeting Ford specification WSK-M2G351-A5.
      Fig 6: Tightening Differential Ring Gear Bolts Alternately
      G02768779Courtesy of FORD MOTOR CO.
  7. Install the original outboard spacers in the side from which they were removed.
    • Use a light coating of grease to hold the spacers in position.
      Fig 7: Installing Original Outboard Spacers
      G02768780Courtesy of FORD MOTOR CO.
    8. NOTE: Remove all nicks, burrs and dirt from the differential carrier hubs, to allow the differential bearings to rotate freely.
    Fig 8: Installing Special Tool On Differential Carrier Hubs
    G02768781Courtesy of FORD MOTOR CO.
  8. 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.
    9. NOTE: Use a dial indicator with a minimum travel capability of 5.08 mm (0.200 in).
    Fig 9: Mounting Special Tools On Flat Surface Of Differential Ring Gear Bolts
    G02768782Courtesy of FORD MOTOR CO.
  9. Mount the special tools as shown. Locate the tip of special tool on the flat surface of one of the differential ring gear bolts.
    10. 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.
    Fig 10: Forcing Differential Carrier Toward Indicator
    G02768783Courtesy of FORD MOTOR CO.
  10. Force the differential carrier as far as possible toward the indicator. With force still applied, zero the indicator.
  11. Force the differential carrier as far as it will go in the opposite direction. Record the total differential carrier end play reading.
    Fig 11: Forcing Differential Carrier In Opposite Direction Of Indicator
    G02768784Courtesy of FORD MOTOR CO.
  12. 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: Removing special tools and differential carrier from axle housing
    G02768785Courtesy of FORD MOTOR CO.
    13. CAUTION: 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.
  13. 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.
    7. Thread on the special tool.
      Fig 13: Positioning Special Tools
      G02768786Courtesy of FORD MOTOR CO.
  14. Install the special tool.
    1. Position the 205-D038 special tool.
    2. Install the differential bearing caps.
    3. Install the differential bearing cap bolts.
      • Tighten to 108 Nm (80 lb-ft).
        Fig 14: Tightening Differential Bearing Cap Bolts
        G02768787Courtesy of FORD MOTOR CO.
  15. 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.
    1. Available
    2. Inner Drive
    3. Pinion
    4. Bearing
    5. Shims
      MATERIAL SPECIFICATION

      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
    16. 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.
  16. 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.
      Fig 15: Measuring Gap Between Special Tools
      G02768788Courtesy of FORD MOTOR CO.
  17. 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.
    18. 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.
    Fig 16: Installing Pinion Bearing Using Special Tool And Press
    G02768789Courtesy of FORD MOTOR CO.
  18. Using the special tool and a suitable press, install the pinion bearing.
  19. 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.
  20. Install the outer pinion bearing and drive pinion oil slinger.
    21. NOTE: The pinion flange must never be hammered on or installed with power tools.
    Fig 17: Installing Pinion Flange Using Special Tool
    G02768790Courtesy of FORD MOTOR CO.
  21. Using the special tool, install the pinion flange.
  22. Use a suitable 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: Tightening Washer And Pinion Nut Using Suitable Tool
      G02768791Courtesy of FORD MOTOR CO.
  23. Using a Nm (lb-in) torque wrench, rotate the pinion. The rotational torque must read 2.9-5.0 Nm (25-45 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: Rotating Pinion Using Torque Wrench
      G02768792Courtesy of FORD MOTOR CO.
  24. While using a suitable tool to prevent the pinion flange from turning, remove the old washer and pinion nut.
    Fig 20: Removing Washer And Pinion Nut Using Suitable Tool
    G02768793Courtesy of FORD MOTOR CO.
  25. Using the special tool, remove the pinion flange.
    Fig 21: Removing Pinion Flange Using Special Tool
    G02768794Courtesy of FORD MOTOR CO.
    26. CAUTION: 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.
  26. Using the special tool, drive the pinion seal into the housing.
    • Coat the pinion seal (rubber lips) with axle lubricant.
      Fig 22: Installing Drive Pinion Seal Into Housing Using Special Tool
      G02768795Courtesy of FORD MOTOR CO.
    27. NOTE: The pinion flange must never be hammered on or installed with power tools.
    Fig 23: Installing Pinion Flange Using Special Tool
    G02768796Courtesy of FORD MOTOR CO.
  27. Using the special tool, install the pinion flange.
  28. 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: Tightening Washer And Pinion Nut Using Special Tool
      G02768797Courtesy of FORD MOTOR CO.
  29. 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: Rotating Pinion Using Torque Wrench
    G02768798Courtesy of FORD MOTOR CO.
  30. Position the differential carrier assembly with the Master Bearings 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: Installing Special Tools
    G02768799Courtesy of FORD MOTOR CO.
  31. Force the differential case away from the drive pinion. With force still applied, set the indicator to zero.
    Fig 27: Forcing Differential Case Away From Drive Pinion
    G02768800Courtesy of FORD MOTOR CO.
    32. 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.
    Fig 28: Forcing Differential Ring Gear Into Mesh With Pinion
    G02768801Courtesy of FORD MOTOR CO.
  32. Force the differential ring gear into mesh with the pinion to obtain the indicator reading. Record the reading.
  33. Remove the special tools and the differential case from the differential housing.
    Fig 29: Removing Special Tools And Differential Case From Differential Housing
    G02768802Courtesy of FORD MOTOR CO.
  34. Remove the Master Bearings from the differential case.
    • Make sure the inner bearing shims remain on the differential carrier hubs.
  35. Using the special tool, install the differential bearing and shim on the LH side of the differential case.
    Fig 30: Installing Differential Bearing And Shim Using Special Tool
    G02768803Courtesy of FORD MOTOR CO.
  36. 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.
      Fig 31: Installing Differential Bearing Onto Hub Using Special Tool
      G02768804Courtesy of FORD MOTOR CO.
  37. Assemble the differential bearing CUDS to the differential bearings.
  38. Place one outboard spacer of the necessary thickness, as determined from the previous measurement, on the LH side of the differential housing.
  39. 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.
    40. CAUTION: Do not spread the differential housing more than specified.
    CAUTION: Avoid nicking the ring gear teeth and the anti-lock speed sensor ring during assembly.
  40. 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: Removing Special Tools
        G02768805Courtesy of FORD MOTOR CO.
    41. CAUTION: Match the mating letters as noted during disassembly.
  41. Install the bearing caps and bolts, aligning the letters with those on the differential housing.
    • Tighten to 108 Nm (80 lb-ft).
      Fig 33: Aligning mating Letters
      G02768806Courtesy of FORD MOTOR CO.
  42. Confirm the total preload.
    • Using an 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 Torque Using Torque Wrench
      G02768807Courtesy of FORD MOTOR CO.
  43. Using the special tools, measure the differential ring gear and pinion backlash at 3 equally spaced points.
    Fig 35: Measuring Differential Ring Gear And Pinion Backlash Using Special Tools
    G02768808Courtesy of FORD MOTOR CO.
  44. Carry out the tooth contact pattern check to verify the final pinion position is correct. Refer to Rear Drive Axle and Differential .
  45. Install the axle shafts. Refer to WHEEL HUBS & BEARINGS - FULL FLOATING AXLE - DANA .
    46. NOTE: Align the index marks made during removal.
  46. Connect the driveshaft at the axle and install the 4 bolts.
    • Tighten to 103 Nm (76 lb-ft).
      Fig 36: Aligning Index Marks
      G02768809Courtesy of FORD MOTOR CO.
  47. Install the differential housing cover.
  48. Fill the axle with the specified type and amount of fluid.
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