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Home >> Ford >> 2003 >> Cutaway 7.3 F >> Repair and Diagnosis >> External Pages >> Different car >> Section 2127 (Rear Drive Axle/Differential - Ford 10.50-Inch Ring Gear -- F250-F350 Super Duty) >> In-Vehicle Servicing >> Differential Ring And Pinion >> Installation

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. Install the inner and outer bearing cups.
    1. After placing the inner and outer bearing cups in their bores, place the Input Shaft Bearing Cup Installer on the inner pinion bearing cup.
    2. Place the Drive Pinion Bearing Installer on the outer pinion bearing cup.
    3. Install the Rear Axle Draw Bar into the replacer tools.
    2. Fig 1: Identifying Special Tools (205-098, 205-231, 308-391) & Bearing Cups
    GF0049197Courtesy of FORD MOTOR CO.
  2. Tighten the Rear Axle Draw Bar to install the pinion bearing cups into their bores.
    3. Fig 2: Tightening Special Tool (205-098) To Seat Drive Pinion Bearing Cups Into Their Bores
    GF0003196Courtesy of FORD MOTOR CO.
  3. Make sure the cups are correctly seated in their bores.
    • If a feeler gauge of the specification shown in the illustration can be inserted between a cup and the bottom of its bore at any point around the cup, the cup is not correctly seated.
    4. Fig 3: Measuring Clearance Between Cup And Bottom Of Its Bore
    G03878599Courtesy of FORD MOTOR CO.
    NOTE: Install new drive pinion bearings without any additional lubricant since the anti-rust oil provides adequate lubricant without upsetting the drive pinion bearing preload settings.
  4. Assemble and position the Adapter, Drive Pinion Depth Gauge, Gauge Block Adapter, Gauge Tube and Pinion Depth Gauge.
    Item Part Number Description
    1 4621 Pinion bearing (outer)
    2 205-160 Adapter (T80T-4020-F43)
    3 4630 Pinion bearing (inner)
    4 205-423 Drive Pinion Depth Gauge
    5 205-159 Gauge Block Adapter
    (2.1993-inch thick) (T80T-4020-F42)
    6 205-D038 Gauge Tube (4.126-inch OD) (D81T-4020-F51)
    7 205-226 Drive Pinion Depth Gauge/Aligner (T85T-4020-AH1)
    8 4010 Rear axle housing
    9 205-111 Handle (T76P-4020-A11)
    5. Fig 4: Identifying Drive Pinion Bearings Components
    GF0003198Courtesy of FORD MOTOR CO.
    NOTE: This step duplicates final pinion bearing preload.
  5. Tighten the Adapter to achieve the specified rotational torque.
    • Tighten to 2.2 Nm (20 lb-in).
    6. Fig 5: Checking Differential Pinion Bearing Preload
    G03878601Courtesy of FORD MOTOR CO.
    NOTE: The Adapter must be offset to obtain an accurate reading.
  6. Rotate the Adapter several half-turns to make sure of correct seating of the pinion bearings, and position the Adapter.
    7. Fig 6: Rotating Gauge Block Several Half Turns To Make Sure Of Correct Seating Of Drive Pinion Bearings
    G03883649Courtesy of FORD MOTOR CO.
  7. Install the Gauge Tube.
    1. Position the Gauge Tube.
    2. Install the 2 differential bearing caps.
    3. Install the 4 differential bearing cap bolts.
    4. Tighten to 119 Nm (88 lb-ft).
    8. Fig 7: Installing Differential Side Bearing Cap Bolts
    GF0003199Courtesy 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.
  8. Use a drive pinion bearing adjustment shim as a gauge for shim selection.
    9. Fig 8: Identifying Drive Pinion Bearing Adjustment Shim
    GF0003085Courtesy of FORD MOTOR CO.
    NOTE: The same differential pinion bearing used in the shim selection procedure must be used in the final assembly of the axle.
  9. Place the selected shim on the pinion and press the bearing until it is firmly seated on the shaft using the Bearing/Oil Seal Plate and Drive Pinion Bearing Installer.
    10. Fig 9: Identifying Special Tools (205-232, 205-090) On Pinion Bearing
    GF0003200Courtesy of FORD MOTOR CO.
  10. Place a new collapsible spacer on the pinion shaft against the pinion stem shoulder.
    11. Fig 10: Identifying Drive Pinion Collapsible Spacer
    GF0000836Courtesy of FORD MOTOR CO.
  11. Install the outer drive pinion bearing and drive pinion shaft oil slinger.
    12. Fig 11: Identifying Outer Drive Pinion Bearing And Drive Pinion Shaft Oil Slinger
    GF0000839Courtesy of FORD MOTOR CO.
  12. Lubricate the lip of the new drive pinion seal with grease.
  13. Using the Drive Pinion Oil Seal Installer, install the drive pinion oil seal.
    14. Fig 12: Installing Drive Pinion Seal
    G03884437Courtesy of FORD MOTOR CO.
  14. Install the drive pinion in the drive pinion carrier bore from inside the rear axle housing.
    15. Fig 13: Locating Drive Pinion Gear
    GF0000840Courtesy of FORD MOTOR CO.
    NOTE: The Drive Pinion Flange Installer must be used due to tight spline fit.
  15. With the drive pinion in place in the axle housing, install the pinion flange using the Drive Pinion Flange Holding Fixture and Drive Pinion Flange Installer.
    16. Fig 14: Installing Pinion Flange Using Drive Pinion Flange Holding Fixture & Drive Pinion Flange Installer
    GF0049194Courtesy of FORD MOTOR CO.
  16. Position the new pinion nut and washer.
    17. Fig 15: Identifying Pinion Nut & Washer
    GF0049198Courtesy of FORD MOTOR CO.
    NOTE: 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.
  17. Use the Drive Pinion Flange Holding Fixture to hold the pinion flange while tightening the pinion nut.
    • Refer to the torque specification for new pinion bearings in the SPECIFICATIONS .
    • Tighten the pinion nut until the desired rotational torque is reached.
    18. Fig 16: Removing Pinion Nut Using Drive Pinion Flange Holding Fixture To Hold Pinion Flange
    GF0049191Courtesy of FORD MOTOR CO.
    NOTE: If removed, press the speed sensor ring on with the differential ring gear.
  18. Install the differential ring gear.
    1. Place the differential ring gear on the differential assembly.
    2. Hand-start 3 new ring gear bolts to align the holes in the differential ring gear and the differential assembly.
    3. Place the differential assembly and differential ring gear onto the press bed blocks with the differential ring gear teeth facing downward.
    4. Press the differential ring gear into place.
    19. Fig 17: Pressing Differential Ring Gear Into Place
    G03884443Courtesy of FORD MOTOR CO.
  19. Install the remaining 9 new differential ring gear bolts.
    • Tighten to 150 Nm (111 lb-ft).
    20. Fig 18: Differential Ring Gear Bolts
    GF0003136Courtesy of FORD MOTOR CO.
  20. Position the differential case in the rear axle housing.
    • Install a shim on the left side as shown in the illustration.
    21. Fig 19: Identifying Differential Bearing Shim On LH Side
    G03884446Courtesy of FORD MOTOR CO.
    NOTE: The bearing caps must be installed in their original locations and positions.
    NOTE: Apply pressure toward the left side to make sure the left bearing is seated.
  21. Install the left bearing cap and loosely install the 2 bearing cap bolts.
    22. Fig 20: Left Bearing Cap & Bolts
    GF0006501Courtesy of FORD MOTOR CO.
  22. Install progressively larger shims on the right side until the largest shim selected can be assembled by hand.
    23. Fig 21: Installing Right Side Shim
    GF0006502Courtesy of FORD MOTOR CO.
  23. Install the right side bearing cap with 2 bolts and tighten the 4 bolts.
    • Tighten to 119 Nm (88 lb-ft).
    24. Fig 22: Identifying Differential Bearing Cap And Differential Bearing Cap Bolts
    G03878679Courtesy of FORD MOTOR CO.
  24. Rotate the differential case to make sure it rotates freely.
    25. Fig 23: Rotating Differential Case
    GF0006492Courtesy of FORD MOTOR CO.
  25. Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, measure the ring gear backlash.
    • If the backlash is within specification, go to Step 31.
    • If a zero backlash condition occurs, go to Step 26.
    • If the backlash is not within specification, go to Step 27.
    26. Fig 24: Measuring Ring Gear Backlash Using Special Tools (100-002, 308-021)
    G03884451Courtesy of FORD MOTOR CO.
  26. If a zero backlash condition occurs, add a 0.50 mm (0.020 in) shim to the RH side and subtract 0.50 mm (0.020 in) from the LH side to allow backlash indication. Repeat Step 25.
    27. NOTE: If backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness on the other differential bearing shim by the same amount.
  27. To increase or decrease backlash, remove the bearing caps and install a thicker shim and a thinner shim as shown.
    Backlash Change Required Thickness Change Required
    mm Inch mm Inch
    0.025 0.001 0.050 0.002
    0.050 0.002 0.050 0.002
    0.076 0.003 0.101 0.004
    0.101 0.004 0.152 0.006
    0.127 0.005 0.152 0.006
    0.152 0.006 0.203 0.008
    0.177 0.007 0.254 0.010
    0.203 0.008 0.254 0.010
    0.228 0.009 0.304 0.012
    0.254 0.010 0.355 0.014
    0.279 0.011 0.355 0.014
    0.304 0.012 0.406 0.016
    0.330 0.013 0.457 0.018
    0.335 0.014 0.457 0.018
    0.381 0.015 0.508 0.020
    28. Fig 25: Identifying Differential Bearing Shims
    G03884521Courtesy of FORD MOTOR CO.
  28. Install the 2 bearing caps and 4 bearing cap bolts.
    • Tighten to 119 Nm (88 lb-ft).
    29. Fig 26: Identifying Differential Bearing Cap And Differential Bearing Cap Bolts
    G03878679Courtesy of FORD MOTOR CO.
  29. Rotate the differential several times to make sure the differential bearings are correctly seated.
    30. Fig 27: Rotating Differential Case
    GF0006492Courtesy of FORD MOTOR CO.
  30. Using the Dial Indicator with Holding Fixture and Clutch Housing Gauge, recheck the backlash.
    31. Fig 28: Measuring Ring Gear Backlash Using Special Tools (100-002, 308-021)
    G03884451Courtesy of FORD MOTOR CO.
  31. Remove the bearing caps and bolts.
    • To establish differential bearing preload, increase both left and right shim sizes by the specification shown in the illustration.
    • Using the Differential Shim Installer, make sure the differential bearing shims are fully seated and the assembly turns freely.
    32. Fig 29: Installing Differential Bearing Shim Using Special Tool (205-228)
    G03904436Courtesy of FORD MOTOR CO.
  32. Install the 2 bearing caps and 4 bearing cap bolts.
    • Tighten to 119 Nm (88 lb-ft).
    33. Fig 30: Identifying Differential Bearing Cap And Differential Bearing Cap Bolts
    G03878679Courtesy of FORD MOTOR CO.
  33. Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, verify the backlash.
    34. Fig 31: Measuring Ring Gear Backlash Using Special Tools (100-002, 308-021)
    G03884451Courtesy of FORD MOTOR CO.
  34. Apply marking compound and rotate the differential assembly 5 complete revolutions.
  35. Verify an acceptable pattern check. For additional information, refer to DRIVELINE SYSTEM - GENERAL INFORMATION article.
  36. Install the axle shafts. For additional information, refer to Axle Shaft .
    37. NOTE: Make sure the machined surfaces on both the rear axle housing and the differential housing are clean and free of oil before applying the new silicone sealant. The inside of the rear axle must be covered when cleaning the machined surface to prevent contamination.
  37. Clean the gasket mating surface of the rear axle and the differential housing cover.
  38. Apply a new, continuous bead of silicone sealant to the differential housing cover.
    39. Fig 32: Proper Application Of Sealant To Differential Housing Cover
    GF0003119Courtesy of FORD MOTOR CO.
    NOTE: The differential housing cover must be installed within 15 minutes of application of the silicone, or new sealant must be applied. If possible, allow one hour before filling with lubricant to make sure the silicone sealant has properly cured.
  39. Install the differential housing cover and the 12 differential housing cover bolts.
    • For stamped steel housing covers, tighten to 45 Nm (33 lb-ft).
    • For cast aluminum housing covers, tighten to 32 Nm (24 lb-ft).
    40. Fig 33: Locating Differential Housing Cover Bolts
    G03878623Courtesy of FORD MOTOR CO.
    NOTE: For Traction-Lok® axles, first fill the axle with 118 ml (4 oz.) of friction modifier or damage to the axle can occur.
    NOTE: Service refill capacities are determined by filling the axle with the specified lubricant to the specified level below the bottom of the filler hole.
  40. Fill the axle to the level shown with axle lubricant and install the filler plug.
    • Tighten to 30 Nm (22 lb-ft).
    41. Fig 34: Checking Axle Lubricant Fill Level
    G03884460Courtesy of FORD MOTOR CO.
  41. Position the driveshaft and align the index mark on the pinion flange.
    42. Fig 35: Aligning Index Marks On Pinion Flange
    GF0000845Courtesy of FORD MOTOR CO.
    NOTE: The driveshaft centering socket yoke fits tightly on the pinion flange pilot. To make sure that the driveshaft centering socket yoke seats squarely on the pinion flange, tighten the driveshaft flange bolts evenly in a cross pattern.
  42. Install the driveshaft flange bolts.
    • Tighten to 103 Nm (76 lb-ft).
    43. Fig 36: Identifying Driveshaft Flange Bolts
    GF0000834Courtesy of FORD MOTOR CO.
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