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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 723 (Rear Drive Axle/Differential - Ford 9.75-Inch Ring Gear) >> In-Vehicle Repair >> Drive Pinion >> Installation

Drive Pinion: Installation

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    USING 205-024 

  1. Position the special tools and the inner and outer bearing cups in their respective bores.
    1. After placing the inner and 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: Positioning Special Tools And Inner And Outer Bearing Cups In Their Respective Bores
    G01440617Courtesy 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 Their Bores
    G01440618Courtesy of FORD MOTOR CO.

    3. USING 205-153, 205-231, 205-D055 AND 205-387 

  3. Using the special tools, drive the outer pinion bearing cup into the rear axle housing.
    Fig 3: Installing Outer Pinion Bearing Cup Into Rear Axle Housing
    G01440619Courtesy of FORD MOTOR CO.
  4. Using the special tools, drive the inner pinion bearing cup into the axle housing.
    Fig 4: Installing Inner Pinion Bearing Cup Into Axle Housing
    G01440620Courtesy of FORD MOTOR CO.

    5. SETTING PINION DEPTH 

    CAUTION: Whenever the cups are removed, new differential pinion bearings must be installed.
    NOTE: 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 5: Inserting feeler gauge Between Cup And Bottom Of Its Bore
    G01440621Courtesy of FORD MOTOR CO.
  5. Make sure the cups are correctly seated in their bores.
    6. NOTE: Apply only a light oil film on the pinion bearings before assembling the tool.
    Fig 6: Positioning Special Tools And Pinion Bearing Components
    G01440622Courtesy of FORD MOTOR CO.
  6. Assemble and position the special tools.
  7. Tighten the Handle.
    Fig 7: Tightening Pinion Nut
    G01440623Courtesy of FORD MOTOR CO.
    8. NOTE: The special tool must be offset to obtain an accurate reading.
  8. Rotate the special tool several half-turns to make sure of correct seating of the pinion bearings, and position the special tool.
  9. Install the special tool.
    Fig 8: Rotating Special Tool Several Half-Turns To Make Sure Of Correct Seating Of Pinion Bearings
    G01440624Courtesy of FORD MOTOR CO.
    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 Bolts
    G01440625Courtesy 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.
    Fig 10: Identifying Drive Pinion Bearing Adjustment Shim
    G01440626Courtesy of FORD MOTOR CO.
  10. Use a drive pinion bearing adjustment shim as a gauge for shim selection.
    • After the correct shim thickness has been determined, remove the special tool.
  11. Using a press and the special tool, press the pinion bearing until it is firmly seated on the pinion and pinion shim.
    Fig 11: Installing Pinion Bearing
    G01440627Courtesy of FORD MOTOR CO.
  12. Place a new drive pinion collapsible spacer on the pinion shaft against the pinion stem shoulder.
    Fig 12: Placing New Drive Pinion Collapsible Spacer On Pinion Shaft Against Pinion Stem Shoulder
    G01440628Courtesy 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.
    Fig 13: Installing Rear Axle Drive Pinion Shaft Oil Slinger
    G01440629Courtesy of FORD MOTOR CO.
  13. Install the outer pinion bearing cone and roller, the rear axle drive pinion shaft oil slinger and the rear axle drive pinion seal.
    14. NOTE: Coat the lips of the rear axle drive pinion seal with Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.
    Fig 14: Placing Special Tool In Pinion Seal Bore And Drive Rear Axle Drive Pinion Seal Into Place
    G01440630Courtesy of FORD MOTOR CO.
  14. Place the special tool in the pinion seal bore and drive the rear axle drive pinion seal into place.
  15. Install the drive pinion in the drive pinion carrier bore from inside the rear axle housing (4010). Seat the drive pinion with a plastic hammer.
    Fig 15: Installing Drive Pinion In Drive Pinion Carrier Bore From Inside Rear Axle Housing
    G01440631Courtesy of FORD MOTOR CO.
  16. Lubricate the pinion flange splines.
    • Use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.
    17. NOTE: Disregard the scribe marks if a new pinion flange is being installed.
    Fig 16: Aligning Pinion Flange With Drive Pinion Shaft
    G01440632Courtesy of FORD MOTOR CO.
  17. Align the pinion flange with the drive pinion shaft.
  18. With the drive pinion in place in the axle housing, install the pinion flange using the special tool.
    Fig 17: Installing Pinion Flange
    G01440633Courtesy of FORD MOTOR CO.
  19. Position the new pinion nut.
    Fig 18: Positioning New Pinion Nut
    G01440634Courtesy of FORD MOTOR CO.
    20. 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.
    CAUTION: Remove the special tool while taking readings with the Nm (inch-pound) torque wrench.
    Fig 19: Tightening Pinion Nut
    G01440635Courtesy of FORD MOTOR CO.
  20. Using the special tool to hold the pinion flange, tighten the pinion nut.
    • Rotate the pinion occasionally to make sure the cone and roller bearings are seating correctly.
    • Install a Nm (inch-pound) torque wrench on the pinion nut.
    • Rotating the pinion through several revolutions, take frequent cone and roller bearing torque preload readings until the original recorded preload reading is obtained.
      • If the original recorded preload is lower than specifications, tighten to the appropriate specifications for used bearings. If the preload is higher than specification, tighten the nut to the original reading as recorded. Refer to TORQUE SPECIFICATIONS .
  21. Install the differential case. For additional information, refer to DIFFERENTIAL CASE .
  22. Position the driveshaft, and align the marks on the pinion flange.
    Fig 20: Positioning Driveshaft And Aligning Marks On Pinion Flange
    G01440636Courtesy of FORD MOTOR CO.
    23. CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion flange pilot. To make sure that the yoke seats squarely on the flange, tighten the bolts evenly in a cross pattern as shown.
  23. Install the driveshaft.
Fig 21: Installing Driveshaft
G01440637Courtesy of FORD MOTOR CO.
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