Drive Pinion: Assembly

WARNING: This page is about a different car, the 2003 Ford Pickup and 2003 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: For Truetrac® and Trac-Lok® differential assemblies, proceed to Step 7.

NOTE: Use a vice with brass jaws or wood blocks.

Place the differential in a vise.
Lubricate and assembly both differential side gears and differential side gear thrust washers. Lubricate and assemble the differential pinion gears and the differential pinion gear thrust washers.
Install the differential side gears and washers in the differential case. Hold the side gears in place while installing the differential pinion gears in the differential case.

Fig 1: Installing Differential Side Gears And Washers In Differential Case
Courtesy of FORD MOTOR CO.

NOTE: Use a drift to align the pinion gear holes with the pinion shaft holes.

Rotate the differential side gears to align the differential pinion gears with the holes in the differential case for the differential pinion shaft.
Assemble the differential pinion shaft. Use a soft faced hammer to tap on the differential pinion shaft to remove the drift.

Fig 2: Removing Drift Using Soft Faced Hammer To Tap On Differential Pinion Shaft
Courtesy of FORD MOTOR CO.
Align the lock pin hole in the differential case with the differential pinion shaft lock pin hole. Insert the lock pin and peen the metal of the differential case over the differential pinion shaft lock pin in two places, 180 degrees apart to lock it in place.

Fig 3: Inserting Lock Pin And Peen Metal Of Differential Case Over Differential Pinion Shaft Lock Pin
Courtesy of FORD MOTOR CO.

NOTE: Align the tab on the anti-lock speed sensor ring with the slot in the differential case.

NOTE: Apply Threadlock® and Sealer to the new bolts.

Fig 4: Aligning Tab On Anti-Lock Speed Sensor Ring With Slot In Differential Case

Courtesy of FORD MOTOR CO.

Fig 5: Removing Bolts From Differential Case Flange

Courtesy of FORD MOTOR CO.

Start two 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 differential case align.
Press the anti-lock speed sensor on the differential case. The differential case flange acts as a pilot for the anti-lock speed sensor ring.

Fig 6: Pressing Anti-Lock Speed Sensor On Differential Case
Courtesy of FORD MOTOR CO.

NOTE: Apply Threadlock® and Sealer to the new bolt threads.

Fig 7: Installing Ring Gear Bolts Alternately And Evenly To Specifications

Courtesy of FORD MOTOR CO.

Draw up the new ring gear bolts alternately and evenly to specifications.
Install the outboard spacers in the side from which they were removed.

Fig 8: Installing Outboard Spacers In Side From Which They Were Removed
Courtesy of FORD MOTOR CO.

NOTE: Remove all nicks, burrs, dirt, etc. from the differential case hubs, to allow the special tools to rotate freely.

Fig 9: Placing Special Tools Of Differential Case Hubs And Positioning Assembly Into Differential Housing

Courtesy of FORD MOTOR CO.

Place the special tools of the differential case hubs and position the assembly into the differential housing.

NOTE: The rear axle uses a combination of differential bearing shims and selective outboard spacers to control differential case end play. The old outboard spacers provide a good starting point when setting end play. However, if additional shimming is necessary, beyond what the hardened differential bearing shims can provide, select and install different thickness outboard spacers.

Fig 10: Placing Tip Of Clutch Housing Gauge On A Flat Surface Of One Of Bolts

Courtesy of FORD MOTOR CO.

Mount the special tools as shown. Locate the tip of the Clutch Housing Gauge on a flat surface of one of the bolts.

NOTE: Repeat this and the following step until the same readings appear on the indicator each time. This is the total differential bearing shim thickness necessary, less preload. The final calculation occurs later during assembly.

Fig 11: Forcing Differential Case As Far As Possible Toward Indicator

Courtesy of FORD MOTOR CO.

Force the differential case as far as possible toward the indicator. With force applied, set the indicator at 0.
Force the differential case as far as it will go in the opposite direction. Record the total differential case end play reading.

Fig 12: Forcing Differential Case As Far As It Will Go In Opposite Direction
Courtesy of FORD MOTOR CO.
After making sure the reading is repeatable, remove the special tools and the differential from the differential housing. Do not remove the Master Bearings from the differential case at this time.

Fig 13: Removing Special Tools And Differential From Differential Housing
Courtesy of FORD MOTOR CO.
Position the special tools and the inner and outer pinion bearing cups in their respective housing bores.
1. After placing the inner 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 14: Positioning Special Tools And Inner And Outer Pinion Bearing Cups In Their Respective Housing Bores
  Courtesy of FORD MOTOR CO.
Tighten the special tool to seat the pinion bearing cups into their bores.

Fig 15: Tightening Special Tool To Seat Pinion Bearing Cups Into Their Bores
Courtesy of FORD MOTOR CO.

CAUTION: Always install new pinion bearings when installing new bearing cups.

NOTE: If the feeler gauge can fit between a cup and the bottom of its bore at any point around the cup, remove and reseat the cup.

Fig 16: Checking That Cups Have Seated Correctly In Their Bores

Courtesy of FORD MOTOR CO.

Check that the cups have seated correctly in their bores.

CAUTION: 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.

Assemble and position the following in the differential housing.
1. Position the special tool.
2. Position the special tool.
3. Position the inner pinion bearing.
4. Position the special tool.
5. Position the special tool.
6. Position the outer pinion bearing.
7. Thread on the special tool.
  
  Fig 17: Positioning Inner Pinion Bearing And Special Tools
  Courtesy of FORD MOTOR CO.

NOTE: This step simulates pinion bearing preload.

Fig 18: Item Description Chart

Courtesy of FORD MOTOR CO.

Fig 19: Installing Special Tool In Housing

Courtesy of FORD MOTOR CO.

Using a Nm (inch-pound) torque wrench, tighten the Handle to specification.

NOTE: Offset the Gauge Block to obtain an accurate reading.

Fig 20: Positioning Gauge Block And Rotating Gauge Block

Courtesy of FORD MOTOR CO.

Rotate the Gauge Block several half turns to make sure the pinion bearings are correctly seated and position the Gauge Block.
Install the special tool.
1. Position the special tool.
2. Install the bearing caps.
3. Install the four bolts.
  
  Fig 21: Installing Special Tool
  Courtesy of FORD MOTOR CO.

NOTE: The service tools designed for a nominal pinion with 0 etch.

NOTE: Use a feeler gauge or clean, flat drive position shims as a measuring device.

NOTE: Do not attempt to force the feeler gauge or shims between the Gauge Block and the Gauge Tube. A slight drag indicates a correct selection.

Fig 22: Measuring Gap Between Gauge Block And Gauge Tube

Courtesy of FORD MOTOR CO.

Measure between the Gauge Block and the Gauge Tube. Record the measurement. Refer to the Pinion Ring Gear Variation Number for shim selection information.

CAUTION: Follow the drive pinion bearing preload shim and drive pinion position shim assembly as directed or unit failure can result.

Install the correct thickness drive pinion position shim, and the oil slinger, if so equipped, on the pinion.

NOTE: Always use the same new inner pinion bearing installed when taking the measurement for drive pinion position shim selection.

Fig 23: Installing Inner Pinion Bearing Using Special Tools And Suitable Press

Courtesy of FORD MOTOR CO.

Using the special tools and a suitable press, install the inner pinion bearing.

NOTE: Use the thickness of the old drive pinion bearing preload shims as a starting point for setting pinion bearing preload.

Fig 24: Drive Pinion Bearing Preload Shims Specifications

Courtesy of FORD MOTOR CO.

Inspect the drive pinion bearing preload shims for damage. Discard them if necessary. New shims are available in the thickness shown in the following chart.
Available Drive Pinion Bearing Preload Shims
Assemble the drive pinion preload shims onto the pinion and install the pinion into the differential housing.

NOTE: Do not install the pinion oil seal at this time.

Fig 25: Installing Pinion Flange Using Special Tool

Courtesy of FORD MOTOR CO.

Using the special tool, install the pinion flange.
Install the old washer and pinion locknut.

Fig 26: Installing Old Washer And Pinion Locknut
Courtesy of FORD MOTOR CO.
Using a Nm (inch-pound) torque wrench, rotate the pinion. The torque must read as specified.
- To increase the bearing preload, remove drive pinion bearing preload shims. To decrease the preload, add pinion bearing preload shims.
  
  Fig 27: Rotating Pinion Using Torque Wrench
  Courtesy of FORD MOTOR CO.
With the drive pinion bearings at the correct preload as determined in this procedure, remove and discard the pinion locknut and washer.

Fig 28: Removing Pinion Locknut And Washer
Courtesy of FORD MOTOR CO.
Using the special tool, remove the pinion flange.

Fig 29: Removing Pinion Flange Using Special Tool
Courtesy of FORD MOTOR CO.
Coat the pinion seal rubber lips with the specified fill lubricant.
Using a suitable driver, install the differential pinion oil seal.
Coat the inner splines of the pinion flange with lubricant.
Using the special tool, install the pinion flange.

Fig 30: Installing Pinion Flange Using Special Tool
Courtesy of FORD MOTOR CO.

CAUTION: Always use a new washer and locknut.

Fig 31: Installing Washer And Locknut And Torque To Specification

Courtesy of FORD MOTOR CO.

Install the new washer and locknut. Torque to specification.
Install the outboard spacers in the side from which they were removed.

Fig 32: Installing Outboard Spacers In Side From Which They Removed
Courtesy of FORD MOTOR CO.
Place the differential assembly with the special tools in the differential housing.

Fig 33: Placing Differential Assembly With Special Tools In Differential Housing
Courtesy of FORD MOTOR CO.
Install the special tools. Locate the tip of the Clutch Housing Gauge on the flat surface of one of the bolts.

Fig 34: Installing Special Tools And Locating Tip Of Clutch Housing Gauge On Flat Surface Of One Of Bolts
Courtesy of FORD MOTOR CO.

NOTE: Repeat this and the following step until the same readings appear on the indicator each time. This is the differential bearing shim thickness necessary between the differential case and the differential bearing on the differential ring gear side of the differential case.

Fig 35: Forcing Differential Case And Ring Gear Away From Drive Pinion

Courtesy of FORD MOTOR CO.

Fig 36: Forcing Differential Ring Gear Into Mesh With Pinion To Obtain An Indicator Reading

Courtesy of FORD MOTOR CO.

Force the differential case and ring gear away from the drive pinion. With force applied, set the indicator to 0.
Force the differential ring gear into mesh with the pinion to obtain an indicator reading. Record this measurement.
Remove the differential case and the special tools from the differential housing.
Remove the Master Bearings from the differential case.
Place a shim of the thickness determined by the end play between the differential case and the ring gear/pinion on the ring gear side of the differential case. If additional shimming is necessary, beyond what the hardened differential bearing shim can provide, select and install a different thickness outboard spacer.
Using the special tool, install the differential bearing on the differential ring gear side of the differential case.

Fig 37: Installing Differential Bearing On Differential Ring Gear Side Of Differential Case Using Special Tool
Courtesy of FORD MOTOR CO.
Determine the correct shim thickness and place the shim on the differential case hub on the drive pinion side.
- To determine the correct shim thickness, first subtract the thickness of the ring gear side differential case hub shim from the total differential case end play reading recorded earlier. Then, add 0.25mm (0.010 in.) to this amount. This result is the correct thickness of shim to place on the pinion side differential hub. If additional shimming is necessary, beyond what the hardened differential bearing shim can provide, select and install a different thickness outboard spacer.
Using the special tools, install the differential bearing.
1. Place the special tool on the differential bearing to protect it during the installation of the opposite bearing.
2. Using the special tool, drive the differential bearing onto the hub.
  
  Fig 38: Installing Differential Bearing Using Special Tools
  Courtesy of FORD MOTOR CO.
Assemble the differential bearing cups to the differential bearings.

CAUTION: Do not spread the differential housing more than specified.

CAUTION: Avoid nicking the ring gear teeth and the anti-lock speed sensor ring during assembly.

Using the special tools, spread the differential housing to specifications.
1. Use a rawhide hammer to seat the differential in the differential housing.
2. Remove the special tools.
  
  Fig 39: Removing Special Tools
  Courtesy of FORD MOTOR CO.

CAUTION: Match the mating letters as noted during disassembly.

Fig 40: Aligning Letters With Those On Differential Housing And Installing Bearing Caps

Courtesy of FORD MOTOR CO.

Install the bearing caps, aligning the letters with those on the differential housing. Tighten the bolts to specifications.
Confirm the total preload.
- Using a Nm (inch-pound) torque wrench, check the torque to rotate the pinion. The reading must be higher than the initial reading taken without the differential case installed by the amount shown.
  
  Fig 41: Rotating Pinion Using Torque Wrench
  Courtesy of FORD MOTOR CO.
Carry out the Tooth Contact Pattern Check to verify the final pinion position is correct. Refer to DRIVELINE SYSTEM - GENERAL INFORMATION .
Install the axle shafts. Refer to REAR DRIVE AXLE/DIFFERENTIAL-DANA S135 .

CAUTION: Clean both flat surfaces (differential housing and differential cover) with a suitable solvent to remove all traces of oil film.

CAUTION: Install the differential cover within 15 minutes of applying the silicone or it will be necessary to remove and reapply new sealant.

Apply a continuous bead of sealant of the specified thickness to the differential housing cover.
Place two bolts into the differential housing cover at the 8 o'clock and 2 o'clock positions. Install the differential housing cover on the differential housing.
Install the remaining bolts. Tighten the bolts alternately and evenly.
- Allow a one hour cure time before filling the axle with the correct amount of specified lubricant.
  
  Fig 42: Installing Bolts And Tightening Bolts Alternately (F350)
  Courtesy of FORD MOTOR CO.
Install the axle assembly. Refer to Axle Assembly .

Fig 43: Installing Bolts And Tightening Bolts Alternately (F450 And F550)
Courtesy of FORD MOTOR CO.