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Differential Ring And Pinion: Installation

WARNING: This page is about a different car, the 2011 Ford Pickup and 2011 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. Position the inner and outer pinion bearing cups and the Rear Axle Drawbar and Drive Pinion Bearing Cup Installers in their respective axle housing bores.
    1. After placing the inner and outer pinion bearing cups in their bores, place the Drive Pinion Bearing Cup Installer (inner) on the inner pinion bearing cup.
    2. Place the Drive Pinion Bearing Cup Installer (outer) on the outer pinion bearing cup.
    3. Install the Rear Axle Drawbar.
    Fig 1: Positioning Inner And Outer Pinion Bearing Cups Using Drive Pinion Bearing Cup Installers
    G07478171Courtesy of FORD MOTOR CO.
  2. Tighten the Rear Axle Drawbar to seat the pinion bearing cups into their bores.
    Fig 2: Tightening Special Tool To Seat Pinion Bearing Cups
    G07478172Courtesy of FORD MOTOR CO.
  3. Check that the pinion bearing cups have seated correctly in their bores.
    NOTE: If the feeler gauge can fit between a pinion bearing cup and the bottom of its bore at any point around the pinion bearing cup, remove and reseat the pinion bearing cup.
    Fig 3: Checking Pinion Bearing Cups Seating
    G07478173Courtesy of FORD MOTOR CO.
  4. Start 2 new ring gear bolts through the differential case flange, the anti-lock sensor ring and into the differential ring gear to make sure the differential ring gear and the differential case align.
    NOTE: If removed, install the anti-lock speed sensor ring.
    Fig 4: Locating Ring Gear Bolts
    G07478174Courtesy of FORD MOTOR CO.
  5. Press the anti-lock speed sensor ring and differential ring gear on the differential carrier. The differential carrier flange acts as a pilot for the anti-lock speed sensor ring.
    Fig 5: Pressing Anti-Lock Speed Sensor Ring
    G07478175Courtesy of FORD MOTOR CO.
  6. Install the 10 remaining ring gear bolts alternately and evenly.
    • Tighten to 298 Nm (220 lb-ft).
    Fig 6: Locating Ring Gear Bolt
    G07478176Courtesy of FORD MOTOR CO.
  7. Install the outboard spacers in the side from which they were removed.
    Fig 7: Installing Outboard Spacer
    G07478177Courtesy of FORD MOTOR CO.
  8. Place the 0.762 mm (0.030 in) inboard shim and the Dummy Bearing Set on the differential carrier hubs. Position the differential carrier into the axle housing.
    NOTE: Remove all nicks, burrs and dirt from the differential carrier hubs to allow the differential bearings to rotate freely.
    Fig 8: Positioning Differential Carrier Into Axle Housing
    G07478178Courtesy of FORD MOTOR CO.
  9. Mount the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge as shown in illustration. Locate the tip of Clutch Housing Gauge on the flat surface of one of the differential ring gear bolts.
    NOTE: Use a Dial Indicator Gauge with a minimum travel capability of 5.08 mm (0.200 in).
    Fig 9: Identifying Dial Indicator Gauge With Holding Fixture And Clutch Housing Gauge
    G06776623Courtesy of FORD MOTOR CO.
  10. Force the differential carrier as far as possible toward the Dial Indicator Gauge. With force still applied, zero the Dial Indicator Gauge.
    NOTE: Repeat this step and the following step until the same reading appears on the Dial Indicator Gauge each time. Record the reading. This is the total differential outboard bearing spacer thickness required, less preload. The final calculation occurs later during assembly.
    Fig 10: Measuring Differential Case End Play Using Required Tool (Away From Drive Pinion)
    G06776624Courtesy of FORD MOTOR CO.
  11. Force the differential carrier as far as it will go in the opposite direction. Record the total differential carrier end play reading.
    Fig 11: Measuring Differential Case End Play Using Required Tool (Toward Drive Pinion)
    G06776625Courtesy of FORD MOTOR CO.
  12. After making sure the reading is correct, remove the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge and the differential carrier from the axle housing. Do not remove the Dummy Bearing Set bearings or the bearing shims from the differential carrier at this time.
  13. Assemble and position the following in the differential housing.
    NOTE: If any of the gauge surfaces have nicks in them, remove the high spots with a medium India oilstone to prevent erroneous readings.
    NOTE: Apply a light oil film on the pinion bearings before assembling the tools.
    1. Position the Adapter.
    2. Position the Alignment Adapter.
    3. Position the inner pinion bearing.
    4. Position the Drive Pinion Depth Gauge/Aligner.
    5. Position the Adapter.
    6. Position the outer pinion bearing.
    7. Thread on the Handle.
    Fig 12: Positioning Special Tools On Differential Housing
    G06776683Courtesy of FORD MOTOR CO.
  14. Install the Gauge Tube.
    1. Install the differential bearing caps.
    2. Install the differential bearing cap bolts.
      • Tighten to 108 Nm (80 lb-ft).
    Fig 13: Identifying Gauge Tube With Differential Bearing Caps And Bearing Cap Bolts
    G06776684Courtesy of FORD MOTOR CO.
  15. Inspect the drive pinion bearing preload shim for damage. Discard it if necessary. New drive pinion bearing preload shims are available in the thickness shown in the following chart.
    AVAILABLE INNER DRIVE PINION BEARING SHIMS

    mm Inches
    0.36 0.014
    0.38 0.015
    0.41 0.016
    0.46 0.018
    0.51 0.020
    0.53 0.021
    0.56 0.022
    0.58 0.023
    0.76 0.030
  16. Using a feeler gauge or flat, clean drive pinion position shim, measure between the Gauge Tube and Adapter. Record the measurement.
    NOTE: Use a feeler gauge or flat, clean drive pinion position shim as a measuring device.
    NOTE: Do not attempt to force the gauge or drive pinion position shim between the Adapter and Gauge Tube. A slight drag indicates a correct selection.
    Fig 14: Locating Drive Pinion Bearing Adjustment Shim
    G06384552Courtesy of FORD MOTOR CO.
  17. Notice the (+) or (-) etching on both the old and new pinion, and adjust the new shim thickness to compensate for the difference of these 2 figures. If so equipped, include the oil slinger thickness in the total measurement to correctly set pinion depth.
    • For example, a pinion etched with m+8 (+3) requires 0.08 mm (0.003 in) less shimming than a pinion etched "0". This means to increase the mounting distance by the amount etched in the pinion, subtract 0.08 mm (0.003 in) from the drive pinion position shim selected for installation. A pinion etched m-8 (-3), requires 0.08 mm (0.003 in) more shimming than a pinion etched "0". In this instance, add 0.08 mm (0.003 in) to the drive pinion position shim selected for installation to decrease the pinion mounting distance by the amount etched in the pinion.
  18. Using the Bearing/Oil Seal Plate and Drive Pinion Bearing Installer and a suitable press, install the pinion bearing.
    NOTE: Always use the same new inner pinion bearing installed when taking the measurement for drive pinion shim selection.
    NOTE: Position the selected pinion depth shim on the pinion shaft between the inner bearing and the pinion head.
    Fig 15: Locating Pinion Bearing
    G06776686Courtesy of FORD MOTOR CO.
  19. Position the original pinion bearing preload shims on the pinion and install the pinion gear in the pinion gear bore from the rear of the housing.
  20. Install the outer pinion bearing and drive pinion oil slinger.
  21. Using the Drive Pinion Flange Installer, install the pinion flange.
    NOTE: The pinion flange must never be hammered on or installed with power tools or damage to the component may occur.
    Fig 16: Installing Pinion Flange Using Suitable Tool
    G06776593Courtesy of FORD MOTOR CO.
  22. Use the Drive Pinion Flange Holding Fixture to prevent the pinion flange from turning while installing the old washer and the pinion shaft locknut.
    • Tighten to 637 Nm (470 lb-ft).
    Fig 17: Removing Pinion Shaft Locknut Using Suitable Tool
    G06142591Courtesy of FORD MOTOR CO.
  23. Using a Nm (lb-in) torque wrench, rotate the pinion. The rotational torque must read 2.3-4.5 Nm (20-40 lb-in).
    • To increase the drive pinion bearing preload, remove drive pinion bearing preload shims. To decrease the drive pinion bearing preload, add drive pinion bearing shims.
    Fig 18: Rotating Pinion Using Torque Wrench
    G06776689Courtesy of FORD MOTOR CO.
  24. While using a the Drive Pinion Flange Holding Fixture to prevent the pinion flange from turning, remove and discard the old washer and pinion shaft locknut.
    Fig 19: Removing Pinion Shaft Locknut Using Suitable Tool
    G06142591Courtesy of FORD MOTOR CO.
  25. Using the 2 Jaw Puller, remove the pinion flange.
    Fig 20: Removing Pinion Flange Using Special Tool
    G06166751Courtesy of FORD MOTOR CO.
  26. Using the Drive Pinion Oil Seal Installer, drive the pinion seal into the housing.
    NOTE: If the drive pinion seal becomes cocked during installation, remove and install a new one. Make sure the garter spring remains in place during assembly. If the spring is dislodged, a new drive pinion seal must be installed.
    • Coat the pinion seal (rubber lips) with axle lubricant.
    Fig 21: Installing Pinion Seal Using Suitable Tool
    G06166753Courtesy of FORD MOTOR CO.
  27. Using the Drive Pinion Flange Installer, install the pinion flange.
    NOTE: The pinion flange must never be hammered on or installed with power tools.
    Fig 22: Installing Pinion Flange Using Suitable Tool
    G06776593Courtesy of FORD MOTOR CO.
  28. Using the Drive Pinion Flange Holding Fixture, prevent the pinion flange from turning while installing the new washer and pinion shaft locknut.
    • Tighten to 637 Nm (470 lb-ft).
    Fig 23: Removing Pinion Shaft Locknut Using Suitable Tool
    G06142591Courtesy of FORD MOTOR CO.
  29. Using a Nm (lb-in) torque wrench, rotate the pinion. The rotational torque must read 0.6 Nm (5 lb-in) higher with the new pinion seal installed.
    Fig 24: Rotating Pinion Using Torque Wrench
    G06776689Courtesy of FORD MOTOR CO.
  30. Position the differential carrier assembly with the Dummy Bearing Set and inner bearing shims in the axle housing. Install the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge and locate the tip of the Clutch Housing Gauge on a flat surface.
    Fig 25: Positioning Differential Carrier Assembly
    G06776623Courtesy of FORD MOTOR CO.
  31. Force the differential case away from the drive pinion. With force still applied, set the Dial Indicator Gauge to zero.
    Fig 26: Measuring Differential Case End Play Using Required Tool (Away From Drive Pinion)
    G06776624Courtesy of FORD MOTOR CO.
  32. Force the differential ring gear into mesh with the pinion to obtain the Dial Indicator Gauge reading. Record the reading.
    NOTE: Repeat this step and the preceding step until the same reading appears on the Dial Indicator Gauge each time. This is the differential outboard bearing shim thickness increase necessary between the differential bearing and the LH side of the differential case.
    Fig 27: Measuring Differential Case End Play Using Required Tool (Toward Drive Pinion)
    G06776625Courtesy of FORD MOTOR CO.
  33. Remove the differential case from the differential housing.
    Fig 28: Removing Differential Case Using Required Tool
    G06776622Courtesy of FORD MOTOR CO.
  34. Remove the Dummy Bearing Set from the differential case.
    • Make sure the inner bearing shims remain on the differential carrier hubs.
  35. Install the original outboard spacers in the side from which they were removed.
    Fig 29: Installing Outboard Spacer
    G06594702Courtesy of FORD MOTOR CO.
  36. Using the Differential Carrier Bearing Installer, install the differential bearing and shim on the LH side of the differential case.
    Fig 30: Installing Differential Bearing On Differential Case Using Required Tool
    G06776626Courtesy of FORD MOTOR CO.
  37. Using the Differential Carrier Bearing Installer and Differential Carrier Bearing Step Plate, install the differential bearing.
    1. Place the Differential Carrier Bearing Step Plate on the differential bearing to protect it during the installation of the opposite bearing.
    2. Using the Differential Carrier Bearing Installer, drive the differential bearing onto the hub.
    Fig 31: Installing Differential Bearing Using Bearing Insataller
    G06776627Courtesy of FORD MOTOR CO.
  38. Assemble the differential bearing cups to the differential bearings.
  39. Place one outboard spacer of the necessary thickness, as determined from the previous measurement, on the LH side of the differential housing.
  40. Determine the correct outboard spacer thickness and place it on the differential case hub on the RH side.
    • To determine the correct spacer thickness, first, subtract the reading of the previous measurement from the total differential case end play reading. Then, add 0.25 mm (0.010 in) to this amount. This is the correct thickness spacer to place on RH side of the housing.
  41. Using the Differential Carrier Spreader and Dial Indicator Gauge with Holding Fixture, spread the differential housing to the specification.
    NOTE: Do not spread the differential housing more than specified or damage to the housing may occur.
    NOTE: Avoid nicking the ring gear teeth and the anti-lock speed sensor ring during assembly.
    • Use a rawhide hammer to seat the differential into the differential housing pocket.
    Fig 32: Spreading Differential Housing Using Rawhide Hammer
    G06776784Courtesy of FORD MOTOR CO.
  42. Install the 2 bearing caps and 4 bolts, aligning the letters with those on the differential housing.
    NOTE: Match the mating letters as noted during disassembly.
    • Tighten to 108 Nm (80 lb-ft).
    Fig 33: Locating Letters On Differential Bearings
    G06776629Courtesy of FORD MOTOR CO.
  43. Confirm the total preload.
    • Using a Nm (lb-in) torque wrench, check the torque to rotate the pinion. The reading must be higher than the initial reading (taken without the differential carrier installed) with new bearings installed as recommended by the following:
      • 3.54 and 3.73 = 0.9 Nm (8 lb-in)
      • 4.10 and 4.56 = 0.8 Nm (7 lb-in)
      • 4.63 and 5.13 = 0.8 Nm (7 lb-in)
    • If the total preload is too high, remove an equal amount of differential bearing shims from each differential case hub. If the total preload is too low, add an equal amount of differential bearing shims to each differential case hub.
    Fig 34: Rotating Pinion Using Torque Wrench
    G06776689Courtesy of FORD MOTOR CO.
  44. Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, measure the differential ring gear and pinion backlash at 3 equally spaced points.
    Fig 35: Measuring Differential Ring Gear And Pinion Backlash Using Dial Indicator Gauge
    G06142669Courtesy of FORD MOTOR CO.
  45. Carry out the tooth contact pattern check to verify the final pinion position is correct. For additional information, refer to DRIVELINE SYSTEM - GENERAL INFORMATION .
  46. Install the axle shafts. For additional information, refer to WHEEL HUBS AND BEARINGS - FULL FLOATING AXLE - DANA .
  47. Position the driveshaft flange on the pinion flange and install the 4 new bolts.
    NOTE: Align the index marks made during removal.
    • Tighten to 100 Nm (74 lb-ft).
    Fig 36: Locating Index-Marking On Driveshaft Flange And Pinion Flange
    G06597342Courtesy of FORD MOTOR CO.
  48. Apply a continuous bead of sealant to the differential housing cover as shown in illustration.
    NOTE: Install the differential cover within 15 minutes of applying the silicone or it will be necessary to remove and reapply new sealant.
    Fig 37: Locating Sealant Applying Area Of Differential Housing Cover
    G06776630Courtesy of FORD MOTOR CO.
  49. Install the differential housing cover and the 10 bolts.
    • Tighten alternately and evenly to 45 Nm (33 lb-ft).
  50. Fill the axle with the specified type and amount of lubricant.
    NOTE: If possible, allow an hour cure time before filling the axle with the correct amount of specified lubricant.
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