Drive Pinion: Assembly

Initial Assembly 

1. Press the inner pinion bearing onto the pinion.
   Fig 1: Pressing Inner Pinion Bearing Onto Pinion

   Courtesy of FORD MOTOR CO.
2. Press the inner and outer pinion bearing cups into the carrier until seated.
   • Use a 0.0381-mm (0.0015-inch) feeler gauge to verify the bearing cups have completely seated in the bearing bores.
   • Lubricate the bearing cups and cone.
     Fig 2: Pressing Inner And Outer Pinion Bearing Cups Into Carrier

     Courtesy of FORD MOTOR CO.
3. Seat the outer pinion bearing on the pinion.
   1. Seat the inner pinion bearing into the cup by positioning a 152.4 x 152.4 x 152.4-mm (6 x 6 x 6-inch) block of wood under the pinion.
   2. Place the original pinion preload spacer onto the pinion.
   3. Place the outer pinion bearing onto the pinion.
   4. Using a suitable press, seat the outer bearing on the pinion.
      Fig 3: Seating Outer Bearing On Pinion Using Suitable Press

      Courtesy of FORD MOTOR CO.
NOTE: Do not install the pinion seal at this time.
Fig 4: Installing Pinion Flange Using Special Tool
Courtesy of FORD MOTOR CO.
4. Using the special tool, install the pinion flange.
5. Install the hex nut.
   • Using a suitable torque multiplier, tighten the hex nut.
     Fig 5: Installing Hex Nut

     Courtesy of FORD MOTOR CO.

   Measuring pinion bearing preload torque 

6. Measure the torque to rotate.
   • Take torque measurements every fourth revolution.
   • Proceed to Pinion bearing preload adjustment in this procedure if the bearing preload torque is not within the specifications. Proceed to Final assembly in this procedure if the bearing preload torque is within the specifications.
     Fig 6: Measuring Torque To Rotate

     Courtesy of FORD MOTOR CO.

   Pinion bearing preload adjustment 

NOTE: Also refer to the following illustration.
7. Adjust the pinion bearing preload by installing a new pinion bearing preload spacer.
   • To increase the preload, install a thinner spacer. To decrease the preload, install a thicker spacer.
   • The pinion bearing preload spacers are available in sizes from 7.26 to 8.00 mm (0.286 to 0.315 inch).
   • Always measure the new spacer before installing it.
   • On a flat surface, sand the next thicker size spacer with emery cloth to the required thickness to obtain a closer adjustment. Thoroughly wash the spacer to remove the emery cuttings before installation.
   • A 0.0254 mm (0.001 inch) change in the spacer thickness will change the torque rate approximately 3.3894 Nm (30 lb-in).
   • Repeat Measuring pinion bearing preload torque and Pinion bearing preload adjustment in this procedure until the rotational torque is within specifications.
     Fig 7: Installing Thinner Spacer

     Courtesy of FORD MOTOR CO.
     Fig 8: Measuring Pinion Bearing Preload Torque

     Courtesy of FORD MOTOR CO.

   Final assembly 

8. Using a suitable torque multiplier, remove the hex nut.
   Fig 9: Removing Hex Nut Using Suitable Torque Multiplier

   Courtesy of FORD MOTOR CO.
CAUTION: Hammering on the pinion flange will close in the bearing bores and misalign the flange lugs. This will result in premature failure of the journal needle bearings. Serious damage will also occur internally to the differential ring gear and pinion or pinion bearings by hammering on external parts. Remove and install the pinion flange using only the procedures in this article.
Fig 10: Removing Pinion Flange Using Special Tool
Courtesy of FORD MOTOR CO.
9. Using the special tool, remove the pinion flange.
10. Using the special tool, install the pinion seal.
    • A rotational torque of 1.6947-5.0841 Nm (15-45 lb-in) is acceptable with the pinion seal installed.
      Fig 11: Installing Pinion Seal Using Special Tool

      Courtesy of FORD MOTOR CO.
11. Using the special tool, install the pinion flange.
    Fig 12: Installing Pinion Flange Using Special Tool

    Courtesy of FORD MOTOR CO.
12. Apply Stud and Bearing Mount to the pinion threads, and install a new hex nut. Using a suitable torque multiplier, tighten the nut.
    Fig 13: Installing Hex Nut

    Courtesy of FORD MOTOR CO.
13. Assemble the carrier. Refer to Differential Case and Ring Gear .