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Differential Ring And Pinion: Installation

WARNING: This page is about a different car, the 2008 Ford Pickup and 2008 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 Draw Bar 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 Draw Bar.
    2. Fig 1: Special Tools Assembly
    GF0006334Courtesy of FORD MOTOR CO.
  2. Tighten the Rear Axle Draw Bar to seat the pinion bearing cups into their bores.
    3. Fig 2: Installing Pinion Bearing Cups
    GF0006335Courtesy of FORD MOTOR CO.
    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.
  3. Check that the pinion bearing cups have seated correctly in their bores.
    4. Fig 3: Checking Pinion Bearing Cups Have Seated Correctly In Their Bores
    GF0049186Courtesy of FORD MOTOR CO.
    NOTE: Apply threadlock to the 2 new differential ring gear bolts.
    NOTE: If removed, install the anti-lock speed sensor ring.
  4. Start 2 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.
    5. Fig 4: Identifying Bolts In Differential Case Flange, Anti-Lock Sensor Ring & Differential Ring Gear
    GF0006342Courtesy 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.
    6. Fig 5: Pressing Anti-Lock Speed Sensor Ring
    GF0006318Courtesy of FORD MOTOR CO.
  6. Apply threadlock and install the 10 remaining bolts alternately and evenly.
    • Tighten to 298 Nm (220 lb-ft).
    7. Fig 6: Identifying Ring Gear Bolts
    G03883503Courtesy of FORD MOTOR CO.
    NOTE: Remove all nicks, burrs and dirt from the differential carrier hubs to allow the differential bearings to rotate freely.
  7. 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.
    8. Fig 7: Differential Assembly & Special Tools (205-D048) In Differential Housing
    GF0006319Courtesy of FORD MOTOR CO.
    NOTE: Use a Dial Indicator with a minimum travel capability of 5.08 mm (0.200 in).
  8. Mount the Dial Indicator with Holding Fixture and Clutch Housing Gauge as shown. Locate the tip of Clutch Housing Gauge on the flat surface of one of the differential ring gear bolts.
    9. Fig 8: Installing Special Tools (205-D048, 100-002, 308-021)
    GF0006320Courtesy of FORD MOTOR CO.
    NOTE: Repeat this step and the following step until the same reading appears on the Dial Indicator each time. Record the reading. This is the total differential outboard bearing spacer thickness required, less preload. The final calculation occurs later during assembly.
  9. Force the differential carrier as far as possible toward the Dial Indicator. With force still applied, zero the Dial Indicator.
    10. Fig 9: Zeroing Dial Indicator
    GF0006321Courtesy of FORD MOTOR CO.
  10. Force the differential carrier as far as it will go in the opposite direction. Record the total differential carrier end play reading.
    11. Fig 10: Checking Backlash
    GF0006322Courtesy of FORD MOTOR CO.
  11. After making sure the reading is correct, remove the Dial Indicator 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.
    12. 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.
  12. Assemble and position the following in the differential housing.
    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.
    13. Fig 11: Special Tools Assembly With Bearings
    GF0006336Courtesy of FORD MOTOR CO.
  13. Install the Gauge Tube.
    1. Install the differential bearing caps.
    2. Install the differential bearing cap bolts.
    3. Tighten to 108 Nm (80 lb-ft).
    14. Fig 12: Identifying Special Tool (205-D038) & Caps
    GF0006337Courtesy of FORD MOTOR CO.
  14. 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
    15. 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.
  15. Using a feeler gauge or flat, clean drive pinion position shim, measure between the Gauge Tube and Adapter. Record the measurement.
    16. Fig 13: Identifying Drive Pinion Bearing Adjustment Shim
    GF0000838Courtesy of FORD MOTOR CO.
  16. 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.
    17. 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.
  17. Using the Bearing/Oil Seal Plate and Drive Pinion Bearing Installer and a suitable press, install the pinion bearing.
    18. Fig 14: Installing Pinion Bearing
    GF0006339Courtesy of FORD MOTOR CO.
  18. 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.
  19. Install the outer pinion bearing and drive pinion oil slinger.
    20. NOTE: The pinion flange must never be hammered on or installed with power tools or damage to the component may occur.
  20. Using the Drive Pinion Flange Installer, install the pinion flange.
    21. Fig 15: Installing Pinion Flange
    GF0006303Courtesy of FORD MOTOR CO.
  21. Use the Drive Pinion Flange Holding Fixture to prevent the pinion flange from turning while installing the old washer and the pinion nut.
    • Tighten to 637 Nm (470 lb-ft).
    22. Fig 16: Holding Pinion Flange With Special Tool (205-126)
    G03883491Courtesy of FORD MOTOR CO.
  22. 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.
    23. Fig 17: Checking Pinion Rotational Torque
    G03918456Courtesy of FORD MOTOR CO.
  23. While using a the Drive Pinion Flange Holding Fixture to prevent the pinion flange from turning, remove and discard the old washer and pinion nut.
    24. Fig 18: Holding Pinion Flange With Special Tool (205-126)
    G03883491Courtesy of FORD MOTOR CO.
  24. Using the 2-Jaw Puller, remove the pinion flange.
    25. Fig 19: Removing Pinion Flange Using Special Tool (205-D072)
    G03878593Courtesy of FORD MOTOR CO.
    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.
  25. Using the Drive Pinion Oil Seal Installer, drive the pinion seal into the housing.
    • Coat the pinion seal (rubber lips) with axle lubricant.
    26. Fig 20: Installing Rear Axle Drive Pinion Seal
    GF0003073Courtesy of FORD MOTOR CO.
    NOTE: The pinion flange must never be hammered on or installed with power tools.
  26. Using the Drive Pinion Flange Installer, install the pinion flange.
    27. Fig 21: Installing Pinion Flange
    GF0006303Courtesy of FORD MOTOR CO.
  27. Using the Drive Pinion Flange Holding Fixture, prevent the pinion flange from turning while installing the new washer and pinion nut.
    • Tighten to 637 Nm (470 lb-ft).
    28. Fig 22: Holding Pinion Flange With Special Tool (205-126)
    G03883491Courtesy of FORD MOTOR CO.
  28. 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.
    29. Fig 23: Checking Pinion Rotational Torque
    G03918456Courtesy of FORD MOTOR CO.
  29. Position the differential carrier assembly with the Dummy Bearing Set and inner bearing shims in the axle housing. Install the Dial Indicator with Holding Fixture and Clutch Housing Gauge and locate the tip of the Clutch Housing Gauge on a flat surface.
    30. Fig 24: Installing Special Tools (205-D048, 100-002, 308-021)
    GF0006320Courtesy of FORD MOTOR CO.
  30. Force the differential case away from the drive pinion. With force still applied, set the Dial Indicator to zero.
    31. Fig 25: Zeroing Dial Indicator
    GF0006321Courtesy of FORD MOTOR CO.
    NOTE: Repeat this step and the preceding step until the same reading appears on the Dial Indicator each time. This is the differential outboard bearing shim thickness increase necessary between the differential bearing and the LH side of the differential case.
  31. Force the differential ring gear into mesh with the pinion to obtain the Dial Indicator reading. Record the reading.
    32. Fig 26: Checking Backlash
    GF0006322Courtesy of FORD MOTOR CO.
  32. Remove the differential case from the differential housing.
    33. Fig 27: Differential Assembly & Special Tools (205-D048) In Differential Housing
    GF0006319Courtesy of FORD MOTOR CO.
  33. Remove the Dummy Bearing Set from the differential case.
    • Make sure the inner bearing shims remain on the differential carrier hubs.
  34. Install the original outboard spacers in the side from which they were removed.
    35. Fig 28: Outboard Spacers
    GF0006313Courtesy of FORD MOTOR CO.
  35. Using the Differential Carrier Bearing Installer, install the differential bearing and shim on the LH side of the differential case.
    36. Fig 29: Identifying Special Tool (205-D044) For Differential Bearing Installation
    G03883526Courtesy of FORD MOTOR CO.
  36. 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.
    37. Fig 30: Using Special Tools (205-432, 205-D044) To Install Differential Bearing Onto Hub
    GF0006323Courtesy of FORD MOTOR CO.
  37. Assemble the differential bearing cups to the differential bearings.
  38. Place one outboard spacer of the necessary thickness, as determined from the previous measurement, on the LH side of the differential housing.
  39. 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.
    40. 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.
  40. Using the Differential Carrier Spreader and Dial Indicator Gauge with Holding Fixture, spread the differential housing to the specification.
    • Use a rawhide hammer to seat the differential into the differential housing pocket.
    41. Fig 31: Using Special Tool (100-D002, 205-001) To Spread Differential Housing
    G03918287Courtesy of FORD MOTOR CO.
    NOTE: Match the mating letters as noted during disassembly.
  41. Install the 2 bearing caps and 4 bolts, aligning the letters with those on the differential housing.
    • Tighten to 108 Nm (80 lb-ft).
    42. Fig 32: Locating Differential Bearing Caps
    G04414224Courtesy of FORD MOTOR CO.
  42. 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.
    43. Fig 33: Checking Pinion Rotational Torque
    G03918456Courtesy of FORD MOTOR CO.
  43. 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.
    44. Fig 34: Measuring Differential Ring Gear & Pinion Backlash Using Special Tools (100-002, 308-021)
    G03918386Courtesy of FORD MOTOR CO.
  44. Carry out the tooth contact pattern check to verify the final pinion position is correct. For additional information, refer to Rear Drive Axle and Differential .
  45. Install the axle shafts. For additional information, refer to WHEEL HUBS AND BEARINGS - FULL FLOATING AXLE - DANA article.
    46. NOTE: Align the index marks made during removal.
  46. Connect the driveshaft flange and the axle flange and install the 4 bolts.
    • Tighten to 100 Nm (74 lb-ft).
    47. Fig 35: Marking Driveshaft Flange And Pinion Flange
    GF0000833Courtesy of FORD MOTOR CO.
    NOTE: Install the differential cover within 15 minutes of applying the silicone or it will be necessary to remove and reapply new sealant.
  47. Apply a continuous bead of sealant of the specified thickness to the differential housing cover.
    48. Fig 36: Applying A Continuous Bead Of Sealant Of Specified Thickness To Differential Housing Cover
    GF0049185Courtesy of FORD MOTOR CO.
  48. Place 2 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.
  49. Install the 8 remaining bolts. Tighten the bolts alternately and evenly.
    • Tighten to 45 Nm (33 lb-ft).
    • If possible, allow an hour cure time before filling the axle with the correct amount of specified lubricant.
  50. Fill the axle with the specified type and amount of lubricant.
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