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Differential Ring And Pinion: Installation

WARNING: This page is about a different car, the 2012 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: Do not omit the drive pinion bearing oil baffle or damage to the component may occur.
    Fig 1: Locating Drive Pinion Bearing Oil Baffle And Differential Carrier Bearings Installer
    G06125467Courtesy of FORD MOTOR CO.
  1. If removed, position the drive pinion bearing oil baffle on the Differential Carrier Bearings Installer.
  2. Using the Differential Carrier Bearings Installer, install the drive pinion bearing oil baffle.
    Fig 2: Installing Drive Pinion Bearing Oil Baffle Using Differential Carrier Bearings Installer
    G06125468Courtesy of FORD MOTOR CO.
  3. Using the Drive Pinion Bearing Cup Installer, install the drive pinion bearing cups.
    Fig 3: Identifying Drive Pinion Bearing Cups And Drive Pinion Bearing Cup Installer
    G06125469Courtesy of FORD MOTOR CO.
    4. NOTE: Use the same drive pinion bearings and the drive pinion bearing adjustment shim from the drive pinion bearing adjustment shim selection procedure for final assembly or damage to the component may occur.
    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.
    Fig 4: Assembling Adapters
    G06125470Courtesy of FORD MOTOR CO.
    Item Part Number Description
    1 205-109 Adapter for 205-S127 (T76P-4020-A9)
    2 205-105 Adapter for 205-S127 (T76P-4020-A3)
    3 4630 Drive pinion bearing (inner)
    4 205-129 Adapter for 105-S127 (T79P-4020-A18)
    5 205-110 Adapter for 205-S127 (T76P-4020-A10)
    6 4621 Drive pinion bearing (outer)
    7 205-111 Adapter for 205-S127 (T76P-4020-A11)
  4. Assemble and position the Adapters.
    5. NOTE: This step duplicates final drive pinion bearing preload.
  5. Tighten the Adapter.
    • Tighten to 2.2 Nm (20 lb-in).
      Fig 5: Tightening Adapter
      G06125144Courtesy of FORD MOTOR CO.
    6. NOTE: The Adapter must be offset to obtain an accurate reading.
    Fig 6: Positioning Adapter
    G06125472Courtesy of FORD MOTOR CO.
  6. Rotate the Adapter several half-turns to make sure of correct seating of the drive pinion bearings and position the Adapter.
  7. Install the Drive Pinion Gauge Tube.
    1. Position the Drive Pinion Gauge Tube.
    2. Install the 2 differential bearing caps.
    3. Install the 4 differential bearing cap bolts.
      • Tighten to 105 Nm (77 lb-ft).
        Fig 7: Identifying Drive Pinion Gauge Tube, Differential Bearing Cap Bolts And Differential Bearing Caps
        G06125473Courtesy of FORD MOTOR CO.
    8. NOTE: Drive pinion bearing adjustment shims must be flat and clean.
    NOTE: A slight drag should be felt for correct drive pinion bearing adjustment shim selection. Do not attempt to force the drive pinion bearing adjustment shim between the gauge block and the gauge tube. This will minimize selection of a drive pinion bearing adjustment shim thicker than required, which results in a deep tooth contact in final assembly of integral axle assemblies.
  8. Use a drive pinion bearing adjustment shim as a gauge for drive pinion bearing adjustment shim selection.
    • After the correct drive pinion bearing adjustment shim thickness has been determined, remove all of the special tools.
      Fig 8: Selecting Correct Drive Pinion Bearing Adjustment Shim
      G06125474Courtesy of FORD MOTOR CO.
  9. Position the drive pinion bearing adjustment shim and the inner pinion bearing on the new drive pinion gear stem.
    Fig 9: Identifying Pinion Adjustment Shim, Bearing And Differential Pinion Gear
    G06125148Courtesy of FORD MOTOR CO.
    10. NOTE: The same drive pinion bearings from the previous steps must be used.
  10. Install the inner drive pinion bearing.
    • Place the drive pinion bearing adjustment shim on the drive pinion gear.
    • Using a suitable press and the Drive Pinion Bearing Cone Installer, press the inner drive pinion bearing until it is firmly seated on the pinion gear.
      Fig 10: Installing Inner Drive Pinion Bearing
      G06125476Courtesy of FORD MOTOR CO.
  11. Place a new drive pinion collapsible spacer on the drive pinion gear.
    Fig 11: Locating Drive Pinion Collapsible Spacer
    G06125460Courtesy of FORD MOTOR CO.
  12. Install the outer drive pinion bearing.
    Fig 12: Locating Outer Drive Pinion Bearing
    G06125335Courtesy of FORD MOTOR CO.
  13. Install the drive pinion oil slinger.
    Fig 13: Locating Drive Pinion Oil Slinger
    G07957803Courtesy of FORD MOTOR CO.
    14. NOTE: Coat the drive pinion seal lips with long-life grease.
  14. Install the drive pinion seal on the Drive Pinion Oil Seal Installer.
    15. NOTE: If the drive pinion seal becomes misaligned during installation, remove it and install a new drive pinion seal.
    Fig 14: Installing Drive Pinion Seal Using Drive Pinion Oil Seal Installer
    G07403951Courtesy of FORD MOTOR CO.
  15. Using the Drive Pinion Oil Seal Installer, install the drive pinion seal.
  16. Lightly lubricate the drive pinion gear splines with axle lubricant.
  17. Position the drive pinion gear in the axle housing.
    Fig 15: Positioning Drive Pinion Gear In Axle Housing
    G06125222Courtesy of FORD MOTOR CO.
  18. Position the pinion flange onto the pinion shaft while mounted on the Transmission Holding Fixture.
    Fig 16: Positioning Pinion Flange Onto Pinion Shaft While Mounted On Transmission Holding Fixture
    G06125154Courtesy of FORD MOTOR CO.
  19. Using the Drive Pinion Flange Installer, install the pinion flange.
    Fig 17: Installing Pinion Flange Using Drive Pinion Flange Installer
    G07403952Courtesy of FORD MOTOR CO.
  20. Apply a small amount of axle lubricant to the washer side of the new pinion nut and install the new pinion nut.
    21. NOTE: Do not loosen the pinion nut to reduce drive pinion bearing preload under any circumstance. If it is necessary to reduce drive pinion bearing preload, install a new drive pinion collapsible spacer and pinion nut or damage to the component may occur.
  21. Install the Drive Pinion Flange Holding Fixture and tighten the pinion nut. For additional information, refer to the torque specifications  in the Specifications portion of this section.
    • Rotate the drive pinion gear occasionally to make sure the drive pinion bearings are seating correctly. Take frequent drive pinion bearing preload readings by rotating the drive pinion gear with a Nm (lb-in) torque wrench.
      Fig 18: Locating Drive Pinion Flange Holding Fixture And Pinion Nut
      G06125457Courtesy of FORD MOTOR CO.
      Fig 19: Measuring Pinion Bearing Preload
      G07403946Courtesy of FORD MOTOR CO.
  22. Press the left and right differential bearing on the differential carrier.
    1. Position the differential bearing.
    2. Using the Differential Side Bearing Installer, press the differential bearing on the differential carrier.
    • Repeat for the other side.
      Fig 20: Pressing Differential Bearing On Differential Carrier
      G06125487Courtesy of FORD MOTOR CO.
  23. 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 carrier 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.
      Fig 21: Installing Differential Ring Gear
      G06125313Courtesy of FORD MOTOR CO.
  24. Install the 10 new ring gear bolts.
    • Tighten to 128 Nm (95 lb-ft).
      Fig 22: Locating Differential Ring Gear Bolts
      G06125372Courtesy of FORD MOTOR CO.
  25. Install the differential carrier.
    1. Position the differential bearing cups on the differential bearings.
    2. Lower the differential carrier in place.
      Fig 23: Installing Differential Carrier
      G06125490Courtesy of FORD MOTOR CO.
  26. Install a differential bearing shim of the thickness shown in illustration on the LH side of the differential bearing.
    Fig 24: Identifying Differential Bearing Shim Thickness On LH Side Of Differential Bearing
    G06125491Courtesy of FORD MOTOR CO.
    27. NOTE: Apply pressure toward the left side to make sure the left bearing cup is seated.
    Fig 25: Locating Bearing Cap
    G06125492Courtesy of FORD MOTOR CO.
  27. Install the left bearing cap and loosely install the 2 bearing cap bolts.
    28. NOTE: Apply pressure toward the left side to make sure the left bearing cap is seated.
    Fig 26: Locating Thicker Differential Bearing Shims On Right Side
    G06125493Courtesy of FORD MOTOR CO.
  28. Install progressively thicker differential bearing shims on the right side until the thickest differential bearing shim can be inserted by hand.
  29. Install the right bearing cap and 2 bolts.
  30. Tighten the 4 differential bearing cap bolts.
    • Tighten to 105 Nm (77 lb-ft).
  31. Rotate the differential carrier to make sure it turns freely.
  32. Install the Dial Indicator Gauge with Holding Fixture at the 12 o'clock position.
    Fig 27: Installing Dial Indicator Gauge With Holding Fixture At 12 O'Clock Position
    G06125494Courtesy of FORD MOTOR CO.
  33. Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, measure the differential ring gear backlash at 4 equally spaced points.
    1. Attach the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge.
    2. Position the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge tip centrally on a drive tooth.
    3. Zero the Dial Indicator.
    4. Turn the differential ring gear without turning the drive pinion gear. Record the indicator reading. The allowable backlash is 0.203 mm (0.008 in) to 0.305 mm (0.012 in) and must not vary more than 0.101 mm (0.004 in) between points measured. A backlash variation of more than 0.101 mm (0.004 in) between points checked indicates gear/case runout.
      • To correct for a high or low backlash, proceed as follows.
        Fig 28: Measuring Differential Ring Gear Backlash
        G06125166Courtesy of FORD MOTOR CO.
  34. To correct for high or low backlash, increase the thickness of one differential bearing shim and decrease the thickness of the other differential bearing shim by the same amount. Refer to the following tables when adjusting the backlash.
    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
    DIFFERENTIAL SHIM SIZE CHART - 4067

    Numbers of Stripes and Color Code Dimension A
    mm Inch
    2 - C-COAL 7.7978-7.8105 0.3070-0.3075
    1 - C-COAL 7.7470-7.7597 0.3050-0.3055
    5 - BLU 7.6962-7.7089 0.3030-0.3035
    4 - BLU 7.6454-7.6581 0.3010-0.3015
    3 - BLU 7.5946-7.6073 0.2990-0.2995
    2 - BLU 7.5458-7.5565 0.2970-0.2975
    1 - BLU 7.493-7.505 0.2950-0.2955
    5 - PINK 7.4422-7.4549 0.2930-0.2935
    4 - PINK 7.3914-7.4041 0.2910-0.2915
    3 - PINK 7.3406-7.3533 0.2890-0.2895
    2 - PINK 7.2898-7.3025 0.2870-0.2875
    1 - PINK 7.2390-7.2517 0.2850-0.2855
    5 - GRN 7.1882-7.2009 0.2830-0.2835
    4 - GRN 7.1374-7.1501 0.2810-0.2815
    3 - GRN 7.0866-7.0993 0.2790-0.2795
    2 - GRN 7.0358-7.0485 0.2770-0.2775
    1 - GRN 6.9850-7.0485 0.2750-0.2755
    5 - WH 6.9342-6.9469 0.2730-0.2735
    4 - WH 6.8834-6.8961 0.2710-0.2715
    3 - WH 6.8326-6.8453 0.2690-0.2695
    2 - WH 6.7818-6.7945 0.2670-0.2675
    1 - WH 6.7310-6.7437 0.2650-0.2655
    5 - YEL 6.6802-6.6929 0.2630-0.2635
    4 - YEL 6.6294-6.6421 0.2610-0.2615
    3 - YEL 6.5786-6.5913 0.2590-0.2595
    2 - YEL 6.5278-6.5405 0.2570-0.2575
    1 - YEL 6.4770-6.4897 0.2550-0.2555
    5 - ORNG 6.4262-6.4389 0.2530-0.2535
    4 - ORNG 6.3754-6.3881 0.2510-0.2515
    3 - ORNG 6.3246-6.3373 0.2490-0.2495
    2 - ORNG 6.2738-6.2865 0.2470-0.2475
    1 - ORNG 6.2223-6.2357 0.2450-0.2455
    2 - RED 6.1722-6.1849 0.2430-0.2435
    1 - RED 6.1214-6.1341 0.2410-0.2415
  35. Remove the 4 differential bearing cap bolts.
    • Remove the differential carrier.
  36. Measure the thickness of the selected right and left bearing shims.
  37. To establish differential bearing preload, increase both the left and right differential bearing shim thickness by 0.203 mm (0.008 in).
  38. Install the Dial Indicator Gauge with Holding Fixture, Clutch Housing Gauge and Differential Carrier Spreader.
    Fig 29: Identifying Dial Indicator Gauge, Holding Fixture, Clutch Housing Gauge And Differential Carrier Spreader
    G06125453Courtesy of FORD MOTOR CO.
    39. NOTE: Overspreading may damage the differential housing.
    NOTE: Tighten and loosen the differential carrier spreader screw to normalize the housing spreader adapters prior to taking the final Dial Indicator reading.
  39. Spread the differential housing to the specification.
    1. Adjust the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge to zero.
    2. Tighten the screw until spreading the differential housing to the specification.
    3. Remove the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge.
      Fig 30: Spreading Differential Housing
      G06125454Courtesy of FORD MOTOR CO.
    40. NOTE: To avoid galling the case, insert shims with a light coating of grease before installing the differential assembly. If not carried out in this order, the aluminum housing may be damaged.
    Fig 31: Locating Differential Bearing Shims In Differential Housing
    G06125498Courtesy of FORD MOTOR CO.
  40. Place the differential bearing shims in the differential housing.
  41. Install the differential carrier.
    1. Position the differential bearing cups on the differential bearings.
    2. Lower the differential carrier in place between the differential bearing shims.
      Fig 32: Installing Differential Carrier
      G06125490Courtesy of FORD MOTOR CO.
    42. NOTE: Hand-tighten the differential bearing cap bolts prior to releasing the carrier spreader.
    Fig 33: Locating Differential Bearing Cap Bolts
    G06125500Courtesy of FORD MOTOR CO.
  42. Install the 2 differential bearing caps and the 4 differential bearing cap bolts in their original locations and positions.
  43. Loosen and remove the Differential Carrier Spreader.
    Fig 34: Identifying Differential Carrier Spreader
    G06125501Courtesy of FORD MOTOR CO.
  44. Tighten the 4 differential bearing cap bolts.
    • Tighten to 105 Nm (77 lb-ft).
  45. Rotate the differential carrier to make sure it turns freely.
  46. Install the Dial Indicator Gauge with Holding Fixture at the 12 o'clock position.
    Fig 35: Installing Dial Indicator Gauge With Holding Fixture At 12 O'Clock Position
    G06125494Courtesy of FORD MOTOR CO.
  47. Using the Dial Indicator Gauge with Holding Fixture, recheck the ring gear backlash.
    Fig 36: Checking Ring Gear Backlash Using Dial Indicator Gauge With Holding Fixture
    G06125503Courtesy of FORD MOTOR CO.
  48. Apply marking compound and rotate the differential assembly 5 complete revolutions.
  49. Verify an acceptable pattern check. For additional information, refer to DIAGNOSIS AND TESTING  .
  50. Install the 4 bolts and the axle housing tube.
    • Tighten to 73 Nm (54 lb-ft).
      Fig 37: Locating Axle Housing Tube And Bolts
      G06125504Courtesy of FORD MOTOR CO.
  51. Install a new stub shaft seal. For additional information, refer to STUB SHAFT PILOT BEARING AND SEAL  .
  52. Install a new circlip on the intermediate shaft end.
    Fig 38: Locating Intermediate Shaft Circlip
    G07957718Courtesy of FORD MOTOR CO.
  53. Insert the intermediate shaft and engage the circlip with the differential side gear.
  54. Remove the axle assembly from the Transmission Holding Fixture and place it on the bench.
    55. NOTE: Remove all of the silicone gasket and make sure the surfaces are free of oil before applying the new silicone gasket.
    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 correctly cured.
  55. Apply a continuous bead of sealant, of the specified thickness, to the differential housing cover mounting surface as shown in the illustration.
    • Use silicone gasket and sealant.
      Fig 39: Locating Continuous Bead Of Sealant On Differential Housing Cover Mounting Surface
      G06452905Courtesy of FORD MOTOR CO.
  56. Install the differential housing cover and 10 bolts.
    • Tighten to 32 Nm (24 lb-ft).
  57. Install the axle assembly. For additional information, refer to AXLE ASSEMBLY  .
  58. Remove the fill plug and fill the axle assembly with the specified amount and type of axle lubricant.
    • Tighten the fill plug to 25 Nm (18 lb-ft).
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