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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 644 (Rear Drive Axle/Differential - Ford 10.50-Inch Ring Gear -- Excursion & F250-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, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the inner and outer bearing cups.
    1. After placing the inner and outer bearing cups in their bores, place the special tool on the inner pinion bearing cup.
    2. Place the special tool on the outer pinion bearing cup.
    3. Install the special tool into the replacer tools.
      Fig 1: Installing Special Tool Into Replacer Tools
      G02769347Courtesy of FORD MOTOR CO.
  2. Tighten the special tool to install the pinion bearing cups into their bores.
    Fig 2: Installing Pinion Bearing Cups Into Their Bores
    G02769348Courtesy of FORD MOTOR CO.
  3. Make sure the cups are correctly seated in their bores.
    • If a feeler gauge of the specification shown in the illustration 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 3: Inserting Bottom Bore At Any Point Around Cup
      G02769349Courtesy of FORD MOTOR CO.
    4. NOTE: Install new drive pinion bearings without any additional lubricant since the anti-rust oil provides adequate lubricant without upsetting the drive pinion bearing preload settings.
    Fig 4: Installing New Drive Pinion Bearings
    G02769350Courtesy of FORD MOTOR CO.
  4. Assemble and position the special tools.
    PARTS DESCRIPTION

    Item Part Number Description
    1 4621 Pinion bearing (outer)
    2 205-160 Screw (T80T-4020-F43)
    3 4630 Pinion bearing (inner)
    4 205-423 Gauge Disc
    5 205-159 Gauge Block (2. 1993 -inch thick) (T80T-4020-F42)
    6 205-D038 Gauge Tube (4.1 26-inch O.D.) (D81 T-4020-F51 )
    7 205-226 Aligning Adapter (T85T-4020-AH1)
    8 4010 Rear axle housing
    9 205-111 Handle (T76P-4020-A11)
    5. NOTE: This step duplicates final pinion bearing preload.
  5. Tighten the Handle to achieve the specified rotational torque.
    • Tighten to 2.2 Nm (20 lb-in).
      Fig 5: Identifying Duplicates Final Pinion Bearing Preload
      G02769351Courtesy of FORD MOTOR CO.
    6. NOTE: The special tool must be offset to obtain an accurate reading.
    Fig 6: Rotating Special Tool Several Half-Turns
    G02769352Courtesy of FORD MOTOR CO.
  6. Rotate the special tool several half-turns to make sure of correct seating of the pinion bearings, and position the special tool.
  7. Install the special tool.
    1. Position the special tool.
    2. Install the differential side bearing caps.
    3. Install the differential side bearing cap bolts.
      • Tighten to 119 Nm (88 lb-ft).
        Fig 7: Installing Differential Side Bearing Caps
        G02769353Courtesy of FORD MOTOR CO.
    8. 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 the final assembly of integral rear axle assemblies.
  8. 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.
      Fig 8: Identifying Drive Pinion Bearing Shims Must Be Flat And Clean
      G02769354Courtesy of FORD MOTOR CO.
    9. CAUTION: Check the splines on the pinion stem to be sure they are free of burrs. If burrs are evident, remove them by using a fine crocus cloth, working in a rotational motion. Wipe the pinion clean.
    NOTE: The same differential pinion bearing used in the previous procedure must be used in the final assembly of the axle.
    Fig 9: Placing Selected Shim On Pinion
    G02769355Courtesy of FORD MOTOR CO.
  9. Place the selected shim on the pinion and press the bearing until it is firmly seated on the shaft using the special tools.
  10. Place a new collapsible spacer on the pinion shaft against the pinion stem shoulder.
    Fig 10: Placing Collapsible Spacer On Pinion Shaft
    G02769356Courtesy of FORD MOTOR CO.
  11. Install the outer drive pinion bearing and drive pinion shaft oil slinger.
    Fig 11: Installing Outer Drive Pinion Bearing And Drive Pinion Shaft Oil
    G02769357Courtesy of FORD MOTOR CO.
  12. Lubricate the new drive pinion seal with grease.
    Fig 12: Lubricating New Drive Pinion Seal With Grease
    G02769358Courtesy of FORD MOTOR CO.
  13. Install the drive pinion in the drive pinion carrier bore from inside the rear axle housing. Seat the drive pinion with a plastic hammer.
    Fig 13: Installing Drive Pinion In Drive Pinion Carrier Bore
    G02769359Courtesy of FORD MOTOR CO.
  14. Lubricate the pinion flange splines with grease.
    15. CAUTION: The special tool must be used due to tight spline fit.
    Fig 14: Installing Pinion Flange Using Companion Flange
    G02769360Courtesy of FORD MOTOR CO.
  15. With the drive pinion in place in the axle housing, install the pinion flange using the Companion Flange Replacer.
  16. Position the new pinion nut.
    Fig 15: Positioning New Pinion Nut
    G02769361Courtesy of FORD MOTOR CO.
    17. 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.
  17. Use the special tool to hold the pinion flange while tightening the pinion nut.
    • Refer to the TORQUE SPECIFICATION  for new pinion bearings.
    • Tighten the pinion nut until the desired rotational torque is reached.
      Fig 16: Using Special Tool To Hold Pinion Flange
      G02769362Courtesy of FORD MOTOR CO.
    18. NOTE: If removed, press the speed sensor ring on with the differential ring gear.
  18. Install the differential ring gear.
    1. Place the differential ring gear on the differential assembly.
    2. Hand-start 3 ring gear bolts to align the holes in the differential ring gear and the differential assembly.
    3. Place the differential assembly and differential ring gear onto the press bed blocks with the differential ring gear teeth facing downward.
    4. Press the differential ring gear into place.
      Fig 17: Pressing Differential Ring Gear Into Place
      G02769363Courtesy of FORD MOTOR CO.
  19. Install the 12 differential ring gear bolts.
    • Apply stud and bearing mount to the differential ring gear bolts.
    • Tighten to 150 Nm (111 lb-ft).
      Fig 18: Install Differential Ring Gear
      G02769364Courtesy of FORD MOTOR CO.
  20. Position the differential case in the rear axle housing.
    • Install a shim on the left side as shown in the illustration.
      Fig 19: Positioning Differential Case In Rear Axle Housing
      G02769365Courtesy of FORD MOTOR CO.
    21. CAUTION: The bearing caps must be installed in their original locations and positions.
    NOTE: Apply pressure toward the left side to make sure the left bearing is seated.
    Fig 20: Installing Left Bearing Cap
    G02769366Courtesy of FORD MOTOR CO.
  21. Install the left bearing cap and loosely install the bearing cap bolts.
  22. Install progressively larger shims on the right side until the largest shim selected can be assembled by hand.
    Fig 21: Installing Progressively Larger Shims
    G02769367Courtesy of FORD MOTOR CO.
  23. Install the right side bearing cap and tighten the 4 bolts.
    • Tighten to 119 Nm (88 lb-ft).
      Fig 22: Installing Right Side Bearing Cap
      G02769368Courtesy of FORD MOTOR CO.
  24. Rotate the differential case to make sure it rotates freely.
    Fig 23: Rotating Differential Case
    G02769369Courtesy of FORD MOTOR CO.
  25. Using the special tool, measure ring gear backlash.
    • If the backlash is within specification, go to Step  31.
    • If a zero backlash condition occurs, go to Step 26.
    • If the backlash is not within specification, go to Step  27.
      Fig 24: Measuring Ring Gear Backlash
      G02769370Courtesy of FORD MOTOR CO.
  26. If a zero backlash condition occurs, add a 0.50 mm (0.020 inch) shim to the RH side and subtract 0.50 mm (0.020 inch) from the LH side to allow backlash indication. Check backlash. Repeat Step  40.
    27. NOTE: If backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness on the other differential bearing shim by the same amount.
    Fig 25: Installing A Thicker Shim And A Thinner Shim
    G02769371Courtesy of FORD MOTOR CO.
  27. To increase or decrease backlash, remove the bearing caps and install a thicker shim and a thinner shim as shown.
    • If backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness on the other differential bearing shim by the same amount.
      Fig 26: Decreasing Thickness On Other Differential Bearing Shim
      G02769372Courtesy of FORD MOTOR CO.
  28. Install the bearing caps and bearing cap bolts.
    • Tighten to 119 Nm (88 lb-ft).
      Fig 27: Installing Bearing Caps And Bearing Cap
      G02769373Courtesy of FORD MOTOR CO.
  29. Rotate the differential several times to make sure the differential bearings are correctly seated.
    Fig 28: Rotating Differential Several Times
    G02769374Courtesy of FORD MOTOR CO.
  30. Using the special tool, recheck the backlash.
    Fig 29: Using Special Tool Check Backlash
    G02769375Courtesy of FORD MOTOR CO.
  31. Remove the bearing caps and bolts.
    • To establish differential bearing preload, increase both left and right shim sizes by the specification shown in the illustration.
    • Using the special tool, make sure the differential bearing shims are fully seated and the assembly turns freely.
      Fig 30: Removing Bearing Caps
      G02769376Courtesy of FORD MOTOR CO.
  32. Install the bearing caps and bearing cap bolts.
    • Tighten to 119 Nm (88 lb-ft).
      Fig 31: Installing Bearing Caps And Bearing Cap
      G02769377Courtesy of FORD MOTOR CO.
  33. Using the special tool, verify the backlash.
    Fig 32: Using Special Tool Verify Backlash
    G02769378Courtesy of FORD MOTOR CO.
  34. Apply marking compound and rotate the differential assembly 5 complete revolutions.
  35. Verify an acceptable pattern check.
  36. Install the axle shafts. Refer to AXLE SHAFT .
    37. CAUTION: Make sure the machined surfaces on both the rear axle housing and the differential housing are clean and free of oil before applying the new silicone sealant. The inside of the rear axle must be covered when cleaning the machined surface to prevent contamination.
  37. Clean the gasket mating surface of the rear axle and the differential housing cover.
  38. Apply a new, continuous bead of silicone sealant to the differential housing cover.
    Fig 33: Applying A New Continuous Bead Of Silicone Sealant To Differential Housing Cover
    G02769379Courtesy of FORD MOTOR CO.
    39. NOTE: The differential housing cover must be installed within 15 minutes of application of the silicone, or new sealant must be applied. If possible, allow one hour before filling with lubricant to ensure the silicone sealant has properly cured.
  39. Install the differential housing cover and the differential housing cover bolts.
    • Tighten to 45 Nm (33 lb-ft).
      Fig 34: Installing Differential Housing Cover And Differential Housing Cover
      G02769380Courtesy of FORD MOTOR CO.
    40. CAUTION: For Traction-Lok® axles, first fill the axle with 118 ml (4 ounces) of friction modifier.
    NOTE: Service refill capacities are determined by filling the axle with the specified lubricant to the specified level below the bottom of the filler hole.
  40. Fill the axle to the level shown with axle lubricant and install the filler plug.
    • Tighten to 30 Nm (22 lb-ft).
      Fig 35: Installing Filler Plug
      G02769381Courtesy of FORD MOTOR CO.
  41. Position the driveshaft and align the index mark on the pinion flange.
    Fig 36: Positioning Driveshaft And Align Index Mark On Pinion Flange
    G02769382Courtesy of FORD MOTOR CO.
    42. CAUTION: The driveshaft centering socket yoke fits tightly on the pinion flange pilot. To make sure that the driveshaft centering socket yoke seats squarely on the pinion flange, tighten the driveshaft flange bolts evenly in a cross pattern.
  42. Install the driveshaft flange bolts.
    • Tighten to 103 Nm (76 lb-ft).
      Fig 37: Tightening Driveshaft Flange
      G02769383Courtesy of FORD MOTOR CO.
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