Drive Pinion: Installation

Using special tool 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

      Courtesy 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

   Courtesy of FORD MOTOR CO.

Using special tools 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: Driving Outer Pinion Bearing Cup Into Rear Axle Housing

   Courtesy of FORD MOTOR CO.
4. Using the special tools, drive the inner pinion bearing cup into the axle housing.
   Fig 4: Driving Inner Pinion Bearing Cup Into Axle Housing

   Courtesy of FORD MOTOR CO.

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 Fig 5 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
Courtesy of FORD MOTOR CO.
5. Make sure the cups are correctly seated in their bores.
NOTE: Apply only a light oil film on the pinion bearings before assembling the tool.
Fig 6: Assembling And Position Special Tools
Courtesy of FORD MOTOR CO.
6. Assemble and position the special tools.
7. Tighten the Handle.
   Fig 7: Tightening Handle

   Courtesy of FORD MOTOR CO.
NOTE: The special tool must be offset to obtain an accurate reading.
Fig 8: Inspecting Correct Seating Of Pinion Bearings
Courtesy 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 differential side bearing cap bolts.
      Fig 9: Installing Differential Side Bearing Cap Bolts

      Courtesy of FORD MOTOR CO.
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: Checking Pinion Bearing Adjustment Shim

      Courtesy of FORD MOTOR CO.
11. Using a press and the special tool, press the selected shim and pinion bearing until it is firmly seated on the pinion.
    Fig 11: Pressing Selected Shim And Pinion Bearing Firmly Seated On Pinion

    Courtesy of FORD MOTOR CO.
12. Place a new drive pinion collapsible spacer on the pinion shaft.
    Fig 12: Identifying Drive Pinion Collapsible Spacer

    Courtesy of FORD MOTOR CO.
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 Seal
Courtesy of FORD MOTOR CO.
13. Install the outer pinion bearing, the rear axle drive pinion shaft oil slinger and the rear axle drive pinion seal.
NOTE: Coat the lips of the rear axle drive pinion seal with grease.
Fig 14: Installing Rear Axle Drive Pinion Seal
Courtesy of FORD MOTOR CO.
14. Using the special tool, drive the pinion seal into place.
15. Install the drive pinion in the drive pinion carrier bore from inside the rear axle housing.
    Fig 15: Installing Drive Pinion Assembly Into Axle Housing

    Courtesy of FORD MOTOR CO.
16. Lubricate the pinion flange splines with rear axle lubricant.
NOTE: Disregard the scribe marks if a new pinion flange is being installed.
Fig 16: Identifying Index-Mark Pinion Flange In Relation To Drive Pinion
Courtesy 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

    Courtesy of FORD MOTOR CO.
19. Position the new pinion nut.
    Fig 18: Positioning Pinion Nut

    Courtesy of FORD MOTOR CO.
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.
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 less than specification, tighten to the appropriate specification for used bearings. If the preload is greater than specification, tighten the nut to the original reading as recorded. Refer to TORQUE SPECIFICATION .
        Fig 19: Rotating Pinion

        Courtesy of FORD MOTOR CO.
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 Align Marks On Pinion Flange

    Courtesy of FORD MOTOR CO.
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
Courtesy of FORD MOTOR CO.
23. Install the driveshaft.