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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 778 (Rear Drive Axle/Differential - Ford 9.75-Inch Ring Gear) >> In-Vehicle Repair >> Differential Ring and Pinion >> Installation

Differential Ring and Pinion: Installation

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
  1. Position the special tools and the inner and outer drive pinion bearing cups in their respective bores.
    1. Place the special tool on the outer drive pinion bearing cup.
    2. Place the special tool on the inner drive pinion bearing cup.
    3. Install the special tool.
      Fig 1: Assembling Special Tool
      G03884426Courtesy of FORD MOTOR CO.
  2. Tighten the special tool to fully seat the differential drive pinion bearing.
    Fig 2: Tightening Special Tool To Fully Seat Differential Drive Pinion Bearing
    G03884427Courtesy of FORD MOTOR CO.
    3. NOTE: If a feeler gauge of the specification shown 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: Checking Clearance Between Cup And Bore
    G03878664Courtesy of FORD MOTOR CO.
  3. Make sure the differential pinion bearing cups are correctly seated.
    4. CAUTION: Use the same drive pinion bearings and the drive pinion bearing adjustment shim from the drive pinion bearing adjustment shim selection procedure for final assembly.
    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 Drive Pinion Bearings And Special Tools
    G03884429Courtesy of FORD MOTOR CO.
  4. Install the new drive pinion bearings and special tools as shown in Fig 4.
  5. Tighten the special tool to the specified rotational torque.
    • Tighten to 2.2 Nm (20 lb-in).
      Fig 5: Checking Differential Pinion Bearing Preload
      G03878601Courtesy of FORD MOTOR CO.
    6. NOTE: The special tool must be offset to obtain an accurate reading.
    Fig 6: Rotating Special Tool
    G03883649Courtesy of FORD MOTOR CO.
  6. Rotate the special tool several half-turns to make sure of correct seating of the drive pinion bearings, then position the special tool.
  7. Install the special tool.
    1. Position the special tool.
    2. Install the differential bearing caps.
    3. Install the differential bearing cap bolts.
      • Tighten to 105 Nm (77 lb-ft)
        Fig 7: Installing Differential Bearing Cap Bolts
        G03884432Courtesy 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 drive pinion bearing adjustment shim selection. Do not attempt to force the drive pinion bearing adjustment shim between the gauge block and the gauge tube. This will minimize selection of a drive pinion bearing adjustment shim thicker than required, which results in a deep tooth contact in the final assembly of integral axle assemblies.
  8. Use a drive pinion bearing adjustment shim as a gauge for drive pinion bearing adjustment shim selection.
    • After the correct drive pinion bearing adjustment shim thickness has been determined, remove the special tools.
      Fig 8: Checking Pinion Bearing Adjustment Shim
      G03883651Courtesy of FORD MOTOR CO.
  9. Using the special tools, press the drive pinion bearing and drive pinion bearing adjustment shim until they are firmly seated on the pinion gear.
    Fig 9: Installing Inner Pinion Bearing And Pinion Shim On Pinion
    G03884434Courtesy of FORD MOTOR CO.
  10. Place a new drive pinion collapsible spacer on the pinion gear against the pinion gear shoulder.
    Fig 10: Identifying Drive Pinion Collapsible Spacer
    G03878606Courtesy of FORD MOTOR CO.
  11. Install the outer drive pinion bearing and drive pinion shaft oil slinger.
    Fig 11: Identifying Outer Drive Pinion Bearing And Drive Pinion Shaft Oil Slinger
    G03884436Courtesy of FORD MOTOR CO.
  12. Lubricate the new drive pinion seal with grease.
    13. CAUTION: If the new drive pinion seal becomes misaligned during installation, remove the drive pinion seal and install a new drive pinion seal.
    Fig 12: Installing Drive Pinion Seal
    G03884437Courtesy of FORD MOTOR CO.
  13. Using the special tool, install a new drive pinion seal.
  14. Lubricate the pinion flange splines with grease.
  15. Install the pinion gear in the pinion gear bore from inside the axle housing.
    Fig 13: Installing Drive Pinion Assembly Into Axle Housing
    G04583053Courtesy of FORD MOTOR CO.
  16. Using the special tool, install the pinion flange.
    Fig 14: Installing Pinion Flange
    G03884510Courtesy of FORD MOTOR CO.
  17. Position the new pinion nut.
    Fig 15: Positioning Pinion Nut
    G03884298Courtesy of FORD MOTOR CO.
    18. CAUTION: Under no circumstances is the pinion nut to be backed off to reduce drive pinion bearing preload. If reduced drive pinion bearing preload is required, a new drive pinion collapsible spacer and pinion nut must be installed.
    CAUTION: Remove the special tool while taking drive pinion bearing preload readings with the Nm (lb-in) torque wrench.
  18. Using the special tool to hold the pinion flange, tighten the pinion nut.
    • Rotate the drive pinion occasionally to make sure the drive pinion bearings are seating correctly.
    • Install a Nm (lb-in) torque wrench on the pinion nut.
    • Rotating the drive pinion through several revolutions, take frequent drive pinion bearing preload readings until the drive pinion bearing preload specification is obtained.
      Fig 16: Holding Pinion Flange With Special Tool
      G03883491Courtesy of FORD MOTOR CO.
  19. Press the LH and RH differential bearing on the differential assembly.
    Fig 17: Installing Differential Bearings On Differential Case
    G03884442Courtesy of FORD MOTOR CO.
    20. NOTE: If removed, press the speed sensor ring on with the differential ring gear.
  20. 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 18: Installing Differential Ring Gear
      G03884443Courtesy of FORD MOTOR CO.
  21. 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 19: Identifying Ring Gear Bolts
      G03884368Courtesy of FORD MOTOR CO.
  22. Install the differential assembly in the axle housing.
    Fig 20: Placing Differential Case In Rear Axle Housing
    G03878552Courtesy of FORD MOTOR CO.
  23. Install a differential bearing shim on the LH side.
    Fig 21: Installing Differential Bearing Shim On LH Side
    G03884446Courtesy of FORD MOTOR CO.
    24. CAUTION: Index-mark the position of the differential bearing caps as arrows may not be visible. The differential bearing caps must be installed in their original locations and positions.
    NOTE: Apply pressure toward the LH side to make sure the LH differential bearing cap is seated.
    Fig 22: Identifying LH Differential Bearing Cap
    G03878615Courtesy of FORD MOTOR CO.
  24. Install the LH differential bearing cap and loosely install the differential bearing cap bolts.
  25. Install progressively larger differential bearing shims on the RH side until the largest differential bearing shim selected that can be installed by hand.
    Fig 23: Installing Differential Bearing Shims
    G03878555Courtesy of FORD MOTOR CO.
  26. Install the RH side differential bearing cap and tighten the LH side and RH side differential bearing cap bolts.
    • Tighten to 105 Nm (77 lb-ft).
      Fig 24: Identifying Differential Bearing Caps And Differential Bearing Cap Bolts
      G03878679Courtesy of FORD MOTOR CO.
  27. Rotate the differential assembly to make sure it rotates freely.
    Fig 25: Rotating Differential Carrier
    G03878557Courtesy of FORD MOTOR CO.
    28. NOTE: If ring gear backlash is within specification, go to Step  32.
    Fig 26: Measuring Ring Gear Backlash
    G03884451Courtesy of FORD MOTOR CO.
  28. Using the special tools, measure ring gear backlash.
    29. NOTE: The differential bearing caps must be removed before differential bearing shims can be installed.
  29. To increase ring gear backlash, install a thicker differential bearing shim and a thinner differential bearing shim as shown in BACKLASH SPECIFICATION .
    • If ring gear 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.
      BACKLASH SPECIFICATION

      Backlash Change Required Thickness Change Required
      mm In mm In
      0.025 0.001 0.050 0.002
      0.050 0.002 0.050 0.002
      0.076 0.003 0.101 0.004
      0.101 0.004 0.152 0.006
      0.127 0.005 0.152 0.006
      0.152 0.006 0.203 0.008
      0.177 0.007 0.254 0.010
      0.203 0.008 0.254 0.010
      0.228 0.009 0.304 0.012
      0.254 0.010 0.355 0.014
      0.279 0.011 0.355 0.014
      0.304 0.012 0.406 0.016
      0.330 0.013 0.457 0.018
      0.335 0.014 0.457 0.018
      0.381 0.015 0.508 0.020
      Fig 27: Rotating Differential Assembly
      G03878680Courtesy of FORD MOTOR CO.
  30. Rotate the differential assembly several times to make sure the differential bearings are seated.
    Fig 28: Rotating Differential Assembly
    G03878680Courtesy of FORD MOTOR CO.
  31. Using the special tools, recheck the ring gear backlash.
    Fig 29: Measuring Ring Gear Backlash
    G03884451Courtesy of FORD MOTOR CO.
  32. Remove the differential bearing cap bolts and differential bearing caps.
    Fig 30: Removing Differential Bearing Cap Bolts And Differential Bearing Caps
    G03884455Courtesy of FORD MOTOR CO.
    33. NOTE: To establish differential bearing preload, increase both LH and RH differential bearing shim sizes as shown. Make sure differential bearing shims are fully seated and the differential assembly turns freely.
    Fig 31: Installing Differential Bearing Shims
    G03884525Courtesy of FORD MOTOR CO.
  33. Using the special tool, install the differential bearing shims.
  34. Install the differential bearing caps and differential bearing cap bolts.
    • Tighten to 105 Nm (77 lb-ft).
      Fig 32: Installing Differential Bearing Caps And Differential Bearing Cap Bolts
      G03884457Courtesy of FORD MOTOR CO.
  35. Apply marking compound and rotate the differential assembly 5 complete revolutions.
  36. Check and verify an acceptable pattern.
  37. Install the axle shafts. For additional information, refer to AXLE SHAFT .
    38. CAUTION: Make sure the machined surfaces on both the axle housing and the differential housing cover are clean and free of oil before applying the new silicone sealant. The inside of the axle must be covered when cleaning the machined surface to prevent contamination.
  38. Clean the gasket mating surface of the axle and the differential housing cover.
  39. Apply a new, continuous bead of sealant to the differential housing cover.
    Fig 33: Applying A New Continuous Bead Of Sealant To Differential Housing Cover
    G03878622Courtesy of FORD MOTOR CO.
    40. 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.
  40. Install the differential housing cover and the differential housing cover bolts.
    • Tighten to 45 Nm (33 lb-ft).
      Fig 34: Identifying Differential Housing Cover
      G03878623Courtesy of FORD MOTOR CO.
    41. 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.
  41. Fill the axle to the level shown with axle lubricant and install the filler plug.
    • Tighten to 30 Nm (22 lb-ft).
      Fig 35: Checking Axle Lubricant Fill Level
      G03884460Courtesy of FORD MOTOR CO.
  42. Position the driveshaft and align the index mark on the pinion flange.
    Fig 36: Positioning Driveshaft And Align Marks On Pinion Flange
    G03878625Courtesy of FORD MOTOR CO.
    43. 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.
  43. Install the driveshaft flange bolts.
    • Tighten to 103 Nm (76 lb-ft).
      Fig 37: Identifying Index-Mark To Driveshaft And Flange Bolts
      G03878515Courtesy of FORD MOTOR CO.
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