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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 >> Drive Pinion >> Installation

Drive 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 special tools and the inner and outer pinion bearing cups in their respective housing bores.
    1. After placing the inner 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: Installing Special Tool
      G02768819Courtesy of FORD MOTOR CO.
  2. Tighten the special tool to seat the pinion bearing cups into their bores.
    Fig 2: Tightening Special Tool To Seat Pinion Bearing Cups Into Bores
    G02768820Courtesy of FORD MOTOR CO.
    3. CAUTION: Always install new pinion bearings when installing new 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: Identifying Feeler Gauge
    G02768821Courtesy of FORD MOTOR CO.
  3. Check that the cups have seated correctly in their bores.
    4. 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.
  4. 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 4: Positioning Special Tools
      G02768822Courtesy of FORD MOTOR CO.
    5. NOTE: This step simulates pinion bearing preload.
    Fig 5: Identifying Item Description Chart
    G02768823Courtesy of FORD MOTOR CO.
  5. Using a Nm (inch-pound) torque wrench, tighten the Handle to specification.
    MATERIAL SPECIFICATION

    Item Description
    1 Screw
    2 Alignment Adapter
    3 Inner Pinion Bearing
    4 Drive Pinion Depth Gauge/Aligner
    5 Gauge Block
    6 Outer Pinion Bearing
    7 Drive Pinion Depth Gauge/Aligner Handle
    6. NOTE: Offset the Gauge Block to obtain an accurate reading.
    Fig 6: Positioning Gauge Block
    G02768824Courtesy of FORD MOTOR CO.
  6. Rotate the Gauge Block several half turns to make sure the pinion bearings are correctly seated and position the Gauge Block.
  7. Install the special tool.
    1. Position the special tool.
    2. Install the bearing caps.
    3. Install the four bolts.
      Fig 7: Installing Special Tool
      G02768825Courtesy of FORD MOTOR CO.
    8. NOTE: The service tools designed for a nominal pinion with 0 etch.
    NOTE: Use a feeler gauge or clean, flat drive position shims as a measuring device.
    NOTE: Do not attempt to force the feeler gauge or shims between the Gauge Block and the Gauge Tube. A slight drag indicates a correct selection.
    Fig 8: Measuring Gap Between Gauge Block And Gauge Tube
    G02768826Courtesy of FORD MOTOR CO.
  8. Measure between the Gauge Block and the Gauge Tube. Record the measurement. Refer to the PINION RING GEAR VARIATION NUMBER  for shim selection information.
    9. CAUTION: Follow the drive pinion bearing preload shim and drive pinion position shim assembly as directed or unit failure can result.
  9. Install the correct thickness drive pinion position shim, and the oil slinger, if so equipped, on the pinion.
    10. NOTE: Always use the same new inner pinion bearing installed when taking the measurement for drive pinion position shim selection.
    Fig 9: Installing Inner Pinion Bearing Using Special Tools And Press
    G02768827Courtesy of FORD MOTOR CO.
  10. Using the special tools and a suitable press, install the inner pinion bearing.
    11. NOTE: Use the thickness of the old drive pinion bearing preload shims as a starting point for setting pinion bearing preload.
  11. Inspect the drive pinion bearing preload shims for damage. Discard them if necessary. New shims are available in the thickness shown in the following chart.
    1. Available
    2. Drive Pinion
    3. Bearing
    4. Preload
    5. Shims
      MATERIAL SPECIFICATION

      mm Inches
      0.51 0.020
      0.53 0.021
      0.56 0.022
      0.58 0.023
      0.76 0.030
  12. Assemble the drive pinion preload shims onto the pinion and install the pinion into the differential housing.
    13. NOTE: Do not install the pinion oil seal at this time.
    Fig 10: Installing Pinion Flange Using Special Tool
    G02768828Courtesy of FORD MOTOR CO.
  13. Using the special tool, install the pinion flange.
  14. Install the old washer and pinion locknut.
    Fig 11: Installing Washer And Pinion Locknut
    G02768829Courtesy of FORD MOTOR CO.
  15. Using a Nm (inch-pound) torque wrench, rotate the pinion. The torque must read as specified.
    • To increase the bearing preload, remove drive pinion bearing preload shims. To decrease the preload, add pinion bearing preload shims.
      Fig 12: Rotating Pinion Using Torque Wrench
      G02768830Courtesy of FORD MOTOR CO.
  16. With the drive pinion bearings at the correct preload as determined in this procedure, remove and discard the pinion locknut and washer.
    Fig 13: Removing Pinion Locknut And Washer
    G02768831Courtesy of FORD MOTOR CO.
  17. Using the special tool, remove the pinion flange.
    Fig 14: Removing Pinion Flange Using Special Tool
    G02768832Courtesy of FORD MOTOR CO.
  18. Coat the pinion seal rubber lips with the specified fill lubricant.
  19. Using a suitable driver, install the differential pinion oil seal.
  20. Coat the inner splines of the pinion flange with lubricant.
  21. Using the special tool, install the pinion flange.
    Fig 15: Installing Pinion Flange Using Special Tool
    G02768833Courtesy of FORD MOTOR CO.
    22. CAUTION: Always use a new washer and locknut.
    Fig 16: Tightening Washer And Locknut
    G02768834Courtesy of FORD MOTOR CO.
  22. Install the new washer and locknut. Tighten to specification.
  23. Install the differential case and ring gear. Refer to DIFFERENTIAL CASE .
  24. Install the rear driveshaft. Refer to DRIVESHAFT .
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