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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 >> Drive Pinion >> Installation

Drive 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.

Using 205-098 

  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
      G02769277Courtesy 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 Bores
    G02769278Courtesy of FORD MOTOR CO.

    Using 205-D055 and 205-153 

  3. Drive the outer pinion bearing cup into the axle housing, using the special tools.
    Fig 3: Identifying Drive Outer Pinion Bearing Cup Into Axle Housing
    G02769279Courtesy of FORD MOTOR CO.
  4. Drive the inner pinion bearing cup into the axle housing, using the special tools.
    Fig 4: Identifying Drive Inner Pinion Bearing Cup Into Axle Housing
    G02769280Courtesy of FORD MOTOR CO.

    Setting pinion depth 

    5. CAUTION: Whenever the cups are replaced, the differential pinion bearings must also be replaced.
  5. Make sure the cups are properly 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 properly seated.
      Fig 5: Identifying Differential Pinion Bearings
      G02769281Courtesy of FORD MOTOR CO.
    6. NOTE: Apply only a light oil film on the pinion bearings before assembling the tool.
    Fig 6: Applying Pinion Bearings
    G02769282Courtesy of FORD MOTOR CO.
  6. Assemble and position the special tools.
    7. NOTE: This step duplicates final pinion bearing preload.
    Fig 7: Tightening Handle To Achieve Specified Rotational Torque
    G02769283Courtesy of FORD MOTOR CO.
  7. Tighten the Handle to achieve the specified rotational torque.
    8. NOTE: The special tool must be offset to obtain an accurate reading.
    Fig 8: Rotating Special Tool Several Half-Turns To Ensure Proper Seating Of Pinion Bearings
    G02769284Courtesy of FORD MOTOR CO.
  8. Rotate the special tool several half-turns to ensure proper 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 differential side bearing cap bolts.
      Fig 9: Installing Differential Side Bearing Cap
      G02769285Courtesy 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 the final assembly of integral rear axle assemblies.
  10. Use a drive pinion bearing adjustment shim as a gauge for shim selection.
    • After the correct shim thickness has been determined, remove the Gauge Tube.
      Fig 10: Adjusting Shim As A Gauge For Shim Selection
      G02769286Courtesy of FORD MOTOR CO.
    11. 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 following procedure must be used in the final assembly of the axle.
    NOTE: Make sure the press load is not applied to the bearing cage.
    Fig 11: Placing Selected Shim(s) On Pinion
    G02769287Courtesy of FORD MOTOR CO.
  11. Place the selected shim(s) on the pinion and press the bearing until it is firmly seated on the shaft using the special tools.
  12. Place a new collapsible spacer on the pinion shaft against the pinion stem shoulder.
    Fig 12: Placing A New Collapsible Spacer On Pinion Shaft
    G02769288Courtesy 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.
    NOTE: Coat the lips of the rear axle drive pinion seal with premium long-life grease.
  13. Install a new rear axle drive pinion seal.
    1. Install the outer pinion bearing roller.
    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 and install the seal.
      Fig 13: Installing Rear Axle Drive Pinion Seal (1 Of 2)
      G02769289Courtesy of FORD MOTOR CO.
      Fig 14: Installing Rear Axle Drive Pinion Seal (2 Of 2)
      G02769290Courtesy of FORD MOTOR CO.
  14. 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 15: Installing The Drive Pinion In Drive Pinion Carrier Bore
    G02769291Courtesy of FORD MOTOR CO.
  15. Lubricate the pinion flange splines with clean synthetic rear axle lubricant.
    16. NOTE: Disregard the scribe marks if a new pinion flange is being installed.
    Fig 16: Aligning Pinion Flange With Drive Pinion Shaft
    G02769292Courtesy of FORD MOTOR CO.
  16. Align the pinion flange with the drive pinion shaft.
    17. CAUTION: The special tool must be used due to tight spline fit.
    Fig 17: Installing Pinion Flange Using Companion Flange
    G02769293Courtesy of FORD MOTOR CO.
  17. With the drive pinion in place in the axle housing, install the pinion flange using the Companion Flange Replacer.
  18. Position the new pinion nut.
    Fig 18: Positioning New Pinion Nut
    G02769294Courtesy of FORD MOTOR CO.
    19. 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.
  19. 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 19: Using Special Tool To Hold Pinion Flange
      G02769295Courtesy of FORD MOTOR CO.
    20. NOTE: Align index marks.
    Fig 20: Installing New Bolts
    G02769296Courtesy of FORD MOTOR CO.
    Fig 21: Measuring Rotational Torque
    G02769297Courtesy of FORD MOTOR CO.
  20. Install new bolts and tighten as shown.
  21. Install the differential case. Refer to DIFFERENTIAL CASE .
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