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Home >> Ford >> 2003 >> Cutaway 7.3 F >> Repair and Diagnosis >> External Pages >> Different car >> Section 238 (Rear Drive Axle/Differential - Ford 10.50-Inch Ring Gear -- Excursion & F250-F350 Super Duty) >> In-Vehicle Repair >> Drive Pinion >> Installation

Drive Pinion: Installation

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

Using 205-098 

  1. Install the inner and outer bearing cups.
    1. After placing the inner and outer bearing cups in their bores, place the special tool on the inner pinion bearing cup.
    2. Place the special tool on the outer pinion bearing cup.
    3. Install the special tool into the replacer tools.
      Fig 1: Installing Inner And Outer Bearing Cups
      G01551215Courtesy of FORD MOTOR CO.
  2. Tighten the special tool to install the pinion bearing cups into their bores.
    Fig 2: Installing Pinion Bearing Cups Into Their Bores
    G01551216Courtesy of FORD MOTOR CO.

    Using 205-D055 and 205-153 

  3. Drive the outer pinion bearing cup into the axle housing, using the special tools.
    Fig 3: Driving Outer Pinion Bearing Cup Into Axle Housing
    G01551217Courtesy of FORD MOTOR CO.
  4. Drive the inner pinion bearing cup into the axle housing, using the special tools.
    Fig 4: Driving Inner Pinion Bearing Cup Into Axle Housing
    G01551218Courtesy of FORD MOTOR CO.

    Setting pinion depth 

    5. CAUTION: Whenever the cups are replaced, the differential pinion bearings must also be replaced.
  5. Make sure the cups are properly 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 properly seated.
      Fig 5: Identifying Feeler Gauge
      G01551219Courtesy of FORD MOTOR CO.
    6. NOTE: Apply only a light oil film on the pinion bearings before assembling the tool.
    Fig 6: Parts Number Description Chart
    G01551220Courtesy of FORD MOTOR CO.
    Fig 7: Identifying Differential Parts
    G01551221Courtesy of FORD MOTOR CO.
  6. Assemble and position the special tools.
    7. NOTE: This step duplicates final pinion bearing preload.
    Fig 8: Tightening Handle To Achieve Specified Rotational Torque
    G01551222Courtesy of FORD MOTOR CO.
  7. Tighten the Handle to achieve the specified rotational torque.
    8. NOTE: The special tool must be offset to obtain an accurate reading.
    Fig 9: Rotating Special Tool
    G01551223Courtesy of FORD MOTOR CO.
  8. Rotate the special tool several half-turns to ensure proper seating of the pinion bearings, and position the special tool.
  9. Install the special tool.
    1. Position the special tool.
    2. Install the differential side bearing caps.
    3. Install the differential side bearing cap bolts.
      Fig 10: Installing Differential Side Bearing Cap Bolts
      G01551224Courtesy of FORD MOTOR CO.
    10. 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. This will minimize selection of a pinion shim thicker than required, which results in a deep tooth contact in the final assembly of integral rear axle assemblies.
  10. Use a drive pinion bearing adjustment shim as a gauge for shim selection.
    • After the proper shim thickness has been determined, remove the Gauge Tube.
      Fig 11: Remove Gauge Tube
      G01551225Courtesy of FORD MOTOR CO.
    11. CAUTION: Check the splines on the pinion stem to be sure they are free of burrs. If burrs are evident, remove them by using a fine crocus cloth, working in a rotational motion. Wipe the pinion clean.
    NOTE: The same differential pinion bearing used in the following procedure must be used in the final assembly of the axle.
    NOTE: Make sure the press load is not applied to the bearing cage.
    Fig 12: Placing Selected Shim(s) On Pinion
    G01551226Courtesy of FORD MOTOR CO.
  11. Place the selected shim(s) on the pinion and press the bearing until it is firmly seated on the shaft using the special tools.
  12. Place a new collapsible spacer on the pinion shaft against the pinion stem shoulder.
    Fig 13: Placing Collapsible Spacer On Pinion Shaft Against Pinion Stem Shoulder
    G01551227Courtesy of FORD MOTOR CO.
    13. CAUTION: Installation without the correct tool can result in early seal failure. If the rear axle drive pinion seal becomes cocked during installation, remove it and install a new one.
    NOTE: Coat the lips of the rear axle drive pinion seal with Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.
  13. Install a new rear axle drive pinion seal.
    1. Install the outer pinion bearing cone and roller.
    2. Install the rear axle drive pinion shaft oil slinger in the rear axle housing.
    3. Install the rear axle drive pinion seal on the special tool and install the seal.
      Fig 14: Installing Rear Axle Drive Pinion Seal (1 Of 2)
      G01551228Courtesy of FORD MOTOR CO.
      Fig 15: Installing Rear Axle Drive Pinion Seal (2 Of 2)
      G01551229Courtesy of FORD MOTOR CO.
  14. Install the drive pinion in the drive pinion carrier bore from inside the rear axle housing. Seat the drive pinion with a plastic hammer.
    Fig 16: Installing Drive Pinion In Drive Pinion Carrier Bore From Inside Rear Axle Housing
    G01551230Courtesy of FORD MOTOR CO.
  15. Lubricate the pinion flange splines.
    • Use SAE 75W-140 Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.
    16. NOTE: Disregard the scribe marks if a new pinion flange is being installed.
    Fig 17: Aligning Pinion Flange With Drive Pinion Shaft
    G01551231Courtesy of FORD MOTOR CO.
  16. Align the pinion flange with the drive pinion shaft.
    17. CAUTION: The special tool must be used due to tight spline fit.
    Fig 18: Installing Pinion Flange Using Companion Flange Replacer
    G01551232Courtesy of FORD MOTOR CO.
  17. With the drive pinion in place in the axle housing, install the pinion flange using the Companion Flange Replacer.
  18. Position the new pinion nut.
    Fig 19: Positioning Pinion Nut
    G01551233Courtesy of FORD MOTOR CO.
    19. CAUTION: 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.
  19. Use the special tool 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.
      Fig 20: Tightening Pinion Nut (1 Of 2)
      G01551234Courtesy of FORD MOTOR CO.
      Fig 21: Tightening Pinion Nut (2 Of 2)
      G01551235Courtesy of FORD MOTOR CO.
  20. Install the differential case. Refer to Differential Case .
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