Drive Pinion: Installation

Using Special Tool 205-054 

1. Position the special tools and the inner and outer pinion bearing cups in their respective bores.
   1. After placing the inner and outer bearing cups in their bores, place the special tool on the inner bearing cup.
   2. Place the special tool on the outer bearing cup.
   3. Install the special tool.
      Fig 1: Installing Special Tool

      Courtesy of FORD MOTOR CO.
2. Tighten the special tool to seat the pinion bearing cups in their bores.
   Fig 2: Tightening Special Tool

   Courtesy of FORD MOTOR CO.
CAUTION: Always install new differential pinion bearings when installing new pinion 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 reset the cup.
Fig 3: Inserting Feeler Gauge
Courtesy of FORD MOTOR CO.
3. Check that the cups have seated correctly in their bores.
NOTE: This is an alternate method for installing the pinion bearing cups. Carry out this procedure if pinion bearing cup installation was not done in the previous steps.
Fig 4: Installing Outer Differential Drive Pinion Bearing Cup
Courtesy of FORD MOTOR CO.
4. Using Special Tools 205-153, 205-054, And 205 -D055
   Using the special tools, drive the outer differential drive pinion bearing cup (4616) into the differential housing.
5. Using the special tools, drive the inner rear axle pinion bearing cup (4628) into the differential housing.
   Fig 5: Installing Inner Rear Axle Pinion Bearing Cup

   Courtesy of FORD MOTOR CO.
CAUTION: Always install new differential pinion bearings when installing new pinion 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 6: Inserting Feeler Gauge
Courtesy of FORD MOTOR CO.
6. Check that the cups have seated correctly in their bores.

Setting Pinion Depth 

NOTE: Apply only a light oil film on the differential pinion bearings before assembling the tools.
7. Assemble and position the following in the differential housing.
   1. Position the Adapter for 205-S127.
   2. Position the Adapter for 205-S127.
   3. Position the inner pinion bearing.
   4. Position the Adapter for 205-S127.
   5. Position the Adapter for 205-S127.
   6. Position the outer pinion bearing.
   7. Thread on the Adapter for 205-S127.
      Fig 7: Assembling Differential Housing Components

      Courtesy of FORD MOTOR CO.
NOTE: This step duplicates final differential pinion bearing preload.
Fig 8: Tightening Special Tool
Courtesy of FORD MOTOR CO.
8. Using a N.m (inch/pound) torque wrench, tighten the special tool to specification.
NOTE: Offset the special tool to obtain an accurate reading.
Fig 9: Rotating Special Tool
Courtesy of FORD MOTOR CO.
9. Rotate the special tool several half-turns to make sure the differential pinion bearings seat correctly and position the special tool as shown.
10. Install the special tool.
    1. Position the special tool.
    2. Install the bearing caps.
    3. Install the four bolts.
       Fig 10: Installing Special Tool

       Courtesy of FORD MOTOR CO.
NOTE: Use only flat, clean drive pinion bearing adjustment shims (4663).
NOTE: Selection of too thick a shim results in a deep tooth contact at final assembly. Do not attempt to force the shim between the special tools. A slight drag indicates correct shim selection.
11. Use a drive pinion bearing adjustment shim as a gauge for shim selection.
    • After determining the correct shim thickness, remove the special tools.
      Fig 11: Removing Special Tools

      Courtesy of FORD MOTOR CO.
12. Position the correct thickness drive pinion bearing adjustment shim and the differential pinion bearing on the drive pinion gear. Using a suitable press and the special tools, press the differential pinion bearing until it seats firmly against the drive pinion gear.
    Fig 12: Pressing Differential Pinion Bearing

    Courtesy of FORD MOTOR CO.
13. Place a new collapsible spacer on the pinion shaft against the pinion stem shoulder.
    Fig 13: Placing Collapsible Spacer

    Courtesy of FORD MOTOR CO.
14. Install the outer differential pinion bearing.
    Fig 14: Installing Outer Differential Pinion Bearing

    Courtesy of FORD MOTOR CO.
15. Install the rear axle drive pinion shaft oil slinger.
    Fig 15: Installing Rear Axle Drive Pinion Shaft Oil Slinger

    Courtesy of FORD MOTOR CO.
16. Install the drive pinion assembly (drive pinion, shims, bearing, and the collapsible spacer) into the differential housing bore.
    Fig 16: Installing Drive Pinion Assembly

    Courtesy of FORD MOTOR CO.
NOTE: Coat the rear axle drive pinion seal lips with Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.
Fig 17: Placing Rear Axle Drive Pinion Seal On Special Tool
Courtesy of FORD MOTOR CO.
17. Place the rear axle drive pinion seal on the special tool.
CAUTION: If the rear axle drive pinion seal becomes misaligned during installation, remove it and install a new one.
Fig 18: Positioning Rear Axle Drive Pinion Seal
Courtesy of FORD MOTOR CO.
18. Position the rear axle drive pinion seal in the seal bore, and use the special tool to drive the seal into place.
19. Lubricate the pinion flange splines.
    • Use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A.
NOTE: Disregard the index marks if installing a new pinion flange.
Fig 19: Positioning Pinion Flange
Courtesy of FORD MOTOR CO.
20. Position the pinion flange.
21. Using the special tools, install the pinion flange.
    Fig 20: Installing Pinion Flange

    Courtesy of FORD MOTOR CO.
CAUTION: Do not under any circumstance loosen the nut to reduce preload. If it is necessary to reduce preload, install a new collapsible spacer and nut.
CAUTION: Remove the special tool while taking readings with the N.m (inch-pound) torque wrench.
22. Tighten the nut to set the preload.
    • Rotate the drive pinion occasionally to make sure the differential pinion bearings seat correctly. Take frequent differential pinion bearing torque preload readings by rotating the drive pinion with a N.m (inch-pound) torque wrench.
    • For new differential pinion bearings, tighten the nut to specification. Refer to TORQUE SPECIFICATIONS  for new differential pinion bearings.
    • For used differential pinion bearings, if the preload recorded prior to disassembly is lower than the specification for used bearings, then tighten the nut to specification. Refer to TORQUE SPECIFICATIONS  for used differential pinion bearings.
    • For used differential pinion bearings, if the preload recorded prior to disassembly is higher than the specification for used bearings, then tighten the nut to the original reading as recorded.
      Fig 21: Tightening Nut

      Courtesy of FORD MOTOR CO.

Final assembly 

23. Install the differential assembly in the differential housing. For additional information, refer to DIFFERENTIAL CASE .
CAUTION: Align the index marks.
CAUTION: Install the driveshaft with new bolts. If new bolts are not available, apply Threadlock and Sealer EOAZ-19554 -AA or equivalent meeting Ford specification WSK-M2G351-A5 to the threads of the original bolts.
CAUTION: The driveshaft centering socket yoke fits tightly on the pinion flange pilot. To make sure that the yoke seats squarely on the flange, tighten the bolts evenly in a cross pattern as shown.
Fig 22: Connecting Driveshaft
Courtesy of FORD MOTOR CO.
24. Connect the driveshaft. For additional information, refer to DRIVESHAFT .
25. Lower the vehicle.