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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 646 (Front Drive Axle/Differential -- Excursion & F250-F550 Super Duty) >> Removal And Installation >> Differential Ring and Pinion - Dana 50 >> Installation

Differential Ring and Pinion - Dana 50: Installation

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. Assemble the ring gear to the differential case by alternately and evenly tightening the new bolts.
    • Tighten to 183 Nm (135 lb-ft).
      Fig 1: Tightening Ring Gear Bolt
      G02769649Courtesy of FORD MOTOR CO.
  2. Place the special tool on the differential case hubs and position the assembly into the differential housing.
    Fig 2: Placing Special Tool On Differential Case Hubs
    G02769650Courtesy of FORD MOTOR CO.
    3. NOTE: Use a Dial Indicator with a minimum travel capacity of 5.08 mm (0.200 inch).
    NOTE: Repeat this step until there is a consistent reading.
  3. Determine the total thickness of differential bearing shims to install on the differential case hubs, less the preload, which is calculated later in this procedure. Record this measurement as the total case end play.
    1. Position the special tool.
    2. Position the special tool.
      • Locate the tip of the tool on a flat surface of one of the ring gear bolt spot faces.
    3. Force the ring gear as far as possible toward the special tool.
    4. With the pressure still applied, zero the special tool.
    5. Force the ring gear as far as it will go in the opposite direction.
    6. Record the reading.
      Fig 3: Positioning Special Tool
      G02769651Courtesy of FORD MOTOR CO.
      Fig 4: Forcing Ring Gear
      G02769652Courtesy of FORD MOTOR CO.
  4. Remove the differential case with the special tool from the differential housing.
    • Do not remove the special tool from the differential case hubs.
      Fig 5: Removing Differential Case Using Special Tool
      G02769653Courtesy of FORD MOTOR CO.
  5. Install the inner oil baffle and the inner and outer pinion bearing cups.
    1. Position the oil baffle and the bearing cups in the differential housing.
    2. Place the special tools on the inner and outer bearing cups.
      • Place special tool 205-139 on the outer pinion bearing cup.
      • Place special tool 205-140 on the inner pinion bearing cup.
  6. Install and tighten special tool 205-098 to seat the cups.
    • Remove the special tools after seating the cups.
      Fig 6: Positioning Bearing Cups In Differential Housing
      G02769654Courtesy of FORD MOTOR CO.
      Fig 7: Placing Special Tools On Inner And Outer Bearing Cups
      G02769655Courtesy of FORD MOTOR CO.
    7. 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 8: Identifying Feeler Gauge
    G02769656Courtesy of FORD MOTOR CO.
  7. Check that the cups have seated correctly in their bores.
    8. 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 only a light oil film on the pinion bearings before assembling the tools.
  8. Assemble and position the following in the differential housing.
    1. Position the Adapter 205-160.
    2. Position the Adapter 205-093.
    3. Position the inner pinion bearing.
    4. Position the Adapter 205-157.
    5. Position the Adapter 205-159.
    6. Position the outer pinion bearing.
    7. Thread on the Adapter 205-111.
      Fig 9: Assembling Differential Housing Components
      G02769657Courtesy of FORD MOTOR CO.
    9. NOTE: This step simulates pinion bearing preload.
    Fig 10: Identifying Special Tool Tightening Torque
    G02769658Courtesy of FORD MOTOR CO.
  9. Using a Nm (inch-pound) torque wrench, tighten the special tool to the specification.
    10. NOTE: Offset the special tool to obtain an accurate reading.
    Fig 11: Positioning Special Tool
    G02769659Courtesy of FORD MOTOR CO.
  10. Rotate the special tool several half-turns to seat the pinion bearings. Position the special tool as shown.
  11. Install the special tool.
    1. Position the special tool.
    2. Install the bearing caps.
    3. Install the bolts.
      • Tighten to 108 Nm (80 lb-ft).
        Fig 12: Installing Special Tool
        G02769660Courtesy of FORD MOTOR CO.
    12. NOTE: Use a feeler gauge or flat, clean drive pinion position shims as a measuring device.
    NOTE: Do not attempt to force the gauge or shim between the special tools. A slight drag indicates a correct selection.
  12. Using a feeler gauge or flat, clean drive pinion position shims, measure the gap between the special tools. Record the measurement.
    • Remove the special tools after making the correct shim selection.
      Fig 13: Measuring Gap Between Special Tools
      G02769661Courtesy of FORD MOTOR CO.
    13. CAUTION: Follow the drive pinion bearing preload shim and drive pinion position shim assembly sequence as directed or unit failure can result.
  13. Install the correct thickness drive pinion position shim on the pinion.
    • To change the pinion adjustment, drive pinion position shims are available in the thickness shown in the following charts. Measure each shim separately with a micrometer.

      Available 

      1. Drive
      2. Pinion
      3. Position
      4. Shims
      DRIVE PINION POSITION SHIMS THICKNESS SPECIFICATION

      mm Inches
      1.22 0.048
      1.27 0.050
      1.32 0.052
      1.37 0.054
      1.42 0.056
      1.47 0.058
      1.52 0.060
      1.57 0.062
    14. CAUTION: Follow the drive pinion bearing preload shim and drive pinion position shim assembly sequence as directed or unit failure can result.
  14. Install the correct thickness drive pinion position shim on the pinion.
  15. Using the special tools, install the differential pinion bearing.
    Fig 14: Installing Differential Pinion Bearing Using Special Tools
    G02769662Courtesy of FORD MOTOR CO.
    16. NOTE: Position the new collapsible spacer inside the differential housing before installing the pinion bearing and the oil slinger.
    Fig 15: Installing Oil Slinger
    G02769663Courtesy of FORD MOTOR CO.
  16. Install the new collapsible spacer, the differential pinion bearing and the oil slinger.
  17. Using a suitable driver, install the pinion seal.
    • Lightly coat the pinion seal lip with lubricant.
      Fig 16: Installing Pinion Seal
      G02769664Courtesy of FORD MOTOR CO.
    18. CAUTION: Do not damage the pinion, the bearings, the seal or the cup.
    Fig 17: Inserting Pinion Into Differential Housing
    G02769665Courtesy of FORD MOTOR CO.
  18. Insert the pinion into the differential housing and seat the inner bearing into the bearing cup.
    19. CAUTION: Never use a metal hammer on the pinion flange or install the flange with power tools. If necessary, use a plastic hammer to tap on a tight fitting flange while holding the backside of the drive pinion.
    Fig 18: Installing Flange
    G02769666Courtesy of FORD MOTOR CO.
  19. Lightly coat the flange splines and seal mating area with lubricant, then install the flange with a new washer and nut.
    20. CAUTION: Never back off the pinion nut to reduce preload. If preload reduction is necessary, install a new collapsible spacer and pinion nut.
  20. Tighten the nut.
    • Use the special tool to prevent the flange from turning while tightening the nut. Remove the special tool when taking pinion bearing torque preload readings.
    • Rotate the pinion occasionally to verify that the bearings are seating correctly.
      Fig 19: Tightening Flange Nut Using Special Tools
      G02769667Courtesy of FORD MOTOR CO.
  21. Take frequent pinion bearing torque preload readings.
    • Tighten to a rotational torque of 1.7-3.4 Nm (15-30 lb-in).
      Fig 20: Checking Pinion Bearing Torque Preload
      G02769668Courtesy of FORD MOTOR CO.
  22. Position the differential case with the special tool into the differential housing.
    Fig 21: Positioning Differential Case Using Special Tool
    G02769669Courtesy of FORD MOTOR CO.
    23. NOTE: Repeat this step until there is a consistent reading.
  23. Determine the total thickness of differential bearing shims to install under the differential bearing on the ring gear side of the differential case. Record this measurement, as the shim thickness required for the ring gear side of the differential case.
    1. Position the special tool.
    2. Position the special tool.
    3. Force the ring gear into mesh with the pinion.
      • Rock the ring gear to allow the teeth of the gears to mesh.
    4. With the pressure still applied, zero the special tool.
    5. Force the ring gear away from the pinion.
    6. Record the reading.
      Fig 22: Positioning Special Tool
      G02769670Courtesy of FORD MOTOR CO.
      Fig 23: Forcing Ring Gear
      G02769671Courtesy of FORD MOTOR CO.
  24. Remove the differential case with the special tool from the differential housing.
    • Remove the special tool from the differential case.
      Fig 24: Removing Special Tool From Differential Housing
      G02769672Courtesy of FORD MOTOR CO.
  25. Place the required thickness of differential bearing shims on the ring gear side of the differential case. Refer to the measurement recorded, as the shim thickness required for the ring gear side of the differential case. Differential bearing shims are available in the thickness shown in the following chart.
    • For example, a reading of 1.14 mm (0.045 inch) requires that 1.14 mm (0.045 inch) shims be placed on the ring gear side of the differential case.

      Available 

      1. Differential 
      2. Bearing 
      3. Shims 
      DIFFERENTIAL BEARING SHIMS THICKNESS SPECIFICATION

      mm inches
      0.076 0.003
      0.127 0.005
      0.254 0.010
      0.762 0.030
  26. Using the special tool(s), install the differential bearing.
    Fig 25: Installing Differential Bearing Using Special Tools
    G02769673Courtesy of FORD MOTOR CO.
  27. Determine the total thickness of differential bearing shims to install under the differential bearing on the drive pinion side of the differential case.
    • Subtract the measurement recorded, as the shim thickness required for the ring gear side of the differential case, from the total case end play measurement taken at the beginning of the assembly procedure. Then, add 0.38 mm (0.015 inch) to the total. This is the total amount of differential bearing shims to install under the differential bearing on the drive pinion side of the differential case.
  28. Place the amount of differential bearing shims, as determined by the calculation made in the previous step, on the drive pinion side of the differential case.
  29. Using the special tools, install the differential bearing.
    1. Place the special tool under the bearing to protect it during the bearing installation.
    2. Using the special tool(s), install the bearing.
      Fig 26: Installing Differential Bearing Using Special Tools
      G02769674Courtesy of FORD MOTOR CO.
  30. Position the differential bearing cups on the bearings.
    Fig 27: Positioning Differential Bearing Cups On Bearings
    G02769675Courtesy of FORD MOTOR CO.
    31. CAUTION: Do not spread the differential housing more than specified.
    CAUTION: Do not damage the ring gear and pinion.
  31. Using the special tools, spread the differential housing.
    • Use a soft face hammer to seat the differential into the differential housing.
      • Remove the special tools after seating the differential in the differential housing.
        Fig 28: Spreading Differential Housing
        G02769676Courtesy of FORD MOTOR CO.
    32. CAUTION: Match the positioning of the mating letters on the bearing caps and the differential housing.
  32. Install the bearing caps.
    • Tighten to 109 Nm (80 lb-ft).
      Fig 29: Identifying Mating Letters On Bearing Caps And Differential Housing
      G02769677Courtesy of FORD MOTOR CO.
  33. Using the special tools, measure backlash at three equally spaced points.
    • The backlash must be within the specifications and cannot vary more than 0.05 mm (0.002 in) between points checked. A backlash variation or more than 0.05 mm (0.002 in) indicates gear/case runout.
      • Make the necessary corrections by moving shims from one side of the differential case to the other, until the correct backlash adjustment is achieved.
        • Correct for high backlash by moving the ring gear toward the pinion.
        • Correct for low backlash by moving the ring gear away from the pinion.
          Fig 30: Measuring Backlash Using Special Tools
          G02769678Courtesy of FORD MOTOR CO.
  34. Apply marking compound and rotate the differential assembly 5 complete revolutions.
  35. Verify an acceptable pattern check. Refer to DIAGNOSIS AND TESTING .
    36. CAUTION: Clean the differential housing cover mounting surfaces with a suitable solvent, to remove all traces of oil film or foreign material.
    NOTE: The differential housing cover requires the use of silicone sealant material rather than a gasket.
    NOTE: Install the differential housing cover within 15 minutes of applying the silicone material.
    Fig 31: Applying Specified Bead Of Silicone Rubber Sealer
    G02769679Courtesy of FORD MOTOR CO.
  36. Apply the specified bead of silicone rubber sealer as shown.
    37. CAUTION: Allow one hour curing time before filling the axle with lubricant.
    NOTE: Place two cover bolts into the differential housing cover at the 2 o'clock and 8 o'clock positions. This will help to position the differential housing cover onto the differential housing.
  37. Install the differential housing cover.
    • Tighten to 47 Nm (35 lb-ft).
      Fig 32: Installing Differential Housing Cover
      G02769680Courtesy of FORD MOTOR CO.
  38. Install the axle assembly. Refer to AXLE ASSEMBLY .
  39. Install the axle shaft assemblies and the front wheel hubs. Refer to DRIVESHAFT .
  40. Fill the axle with the specified type and quantity of lubricant.
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