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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 777 (Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear) >> In-Vehicle Repair >> Drive Pinion >> Installation

Drive Pinion: Installation

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    NOTE: This step and the following step show the preferred method for installing the pinion bearing cups. An alternate method is shown following these two steps.
  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: Installing Special Tool
      G03884009Courtesy 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 Their Bores
    G03884010Courtesy of FORD MOTOR CO.
    3. NOTE: The following two steps are alternate methods for installing the pinion bearing cups.
    Fig 3: Using Special Tools
    G03884011Courtesy of FORD MOTOR CO.
  3. Using the special tools, drive the outer pinion bearing cup into the rear axle housing.
  4. Using the special tools, drive the inner pinion bearing cup into the axle housing.
    Fig 4: Identifying Using Special Tools, Drive Inner Pinion Bearing Cup Into Axle Housing
    G03884012Courtesy of FORD MOTOR CO.
    5. CAUTION: Whenever new cups are installed, new pinion bearings must also be installed.
    NOTE: If a feeler gauge 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: Checking Clearance Between Cup And Bore
    G03883828Courtesy 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: Applying Light Oil Film On Pinion Bearings Before Assembling
    G03884014Courtesy of FORD MOTOR CO.
  6. Assemble and position the special tools.
    7. NOTE: This step duplicates final pinion bearing preload.
    Fig 7: Tightening Special Tool
    G03884015Courtesy of FORD MOTOR CO.
  7. Tighten the special tool to the specification shown in Fig 7.
    8. NOTE: The special tool must be offset to obtain an accurate reading.
    Fig 8: Rotating Special Tool Several Half-Turns
    G03884016Courtesy of FORD MOTOR CO.
  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.
    1. Position the special tool.
    2. Install the differential side bearing caps.
    3. Install the four differential side bearing cap bolts.
      Fig 9: Installing Four Differential Side Bearing Cap Bolts
      G03884017Courtesy 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.
  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.
      Fig 10: Identifying Drive Pinion Bearing Adjustment Shim
      G03878604Courtesy of FORD MOTOR CO.
  11. Using the special tools, press the pinion bearing and pinion shim firmly on the pinion.
    Fig 11: Installing Pinion Bearing
    G03884019Courtesy of FORD MOTOR CO.
  12. Place a new drive pinion collapsible spacer against the pinion stem shoulder.
    Fig 12: Identifying Drive Pinion Collapsible Spacer
    G03878606Courtesy 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.
  13. Install a new rear axle drive pinion seal.
    1. Install the front pinion bearing.
    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.
      Fig 13: Installing Rear Axle Drive Pinion Seal On Special Tool
      G03884021Courtesy of FORD MOTOR CO.
    14. NOTE: Coat the lips of the rear axle drive pinion seal with grease.
    Fig 14: Installing Rear Axle Drive Pinion Seal
    G03884022Courtesy of FORD MOTOR CO.
  14. Using the special tool, drive the rear axle drive pinion seal into place.
  15. From inside the rear axle housing, install the drive pinion assembly (drive pinion, shims, rear bearing, and drive pinion collapsible spacer) into the rear axle bore.
    Fig 15: Installing Drive Pinion Assembly Into Axle Housing
    G04583053Courtesy of FORD MOTOR CO.
  16. Lubricate the pinion flange splines with rear axle lubricant.
    17. NOTE: Disregard the scribe marks if a new pinion flange is being installed.
    Fig 16: Aligning Pinion Flange With Drive Pinion Shaft
    G03878652Courtesy of FORD MOTOR CO.
  17. Align the pinion flange with the drive pinion shaft.
  18. With the drive pinion in place in the rear axle housing, install the pinion flange using the special tool.
    Fig 17: Installing Pinion Flange Using Special Tool
    G03883973Courtesy of FORD MOTOR CO.
  19. Position the new pinion nut.
    Fig 18: Identifying Pinion Nut
    G03884026Courtesy 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.
  20. Using the special tool to hold the pinion flange, tighten the pinion nut.
    • Rotate the pinion occasionally to make sure the bearings are seating correctly.
    • Install a Nm (inch-pound) torque wrench on the pinion nut.
    • Rotating the pinion through several revolutions, take frequent 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. For additional information, refer to TORQUE SPECIFICATIONS .
      Fig 19: Holding Pinion Flange With Special Tool
      G03883969Courtesy of FORD MOTOR CO.
  21. Position the rear driveshaft and align the marks on the pinion flange.
    Fig 20: Positioning Driveshaft And Align Marks On Pinion Flange
    G03878625Courtesy of FORD MOTOR CO.
    22. 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 in Fig 21.
    Fig 21: Bolt Tightening Pattern - With Torque Specification
    G03878528Courtesy of FORD MOTOR CO.
  22. Install the new bolts and tighten to specification.
  23. Install the differential case in the rear axle differential. For additional information, refer to DIFFERENTIAL CASE .
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