Differential Ring And Pinion: Installation

WARNING: This page is about a different car, the 2013 Ford F-550 Super Duty, 2013 Ford F-450 Super Duty, 2013 Ford F-350 Super Duty, and 2013 Ford F-250 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.

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 Drawbar into the replacer tools.
  
  Fig 1: Installing Inner And Outer Bearing Cups Using Special Tools
  Courtesy of FORD MOTOR CO.
Tighten the Rear Axle Drawbar to install the pinion bearing cups into their bores.

Fig 2: Tightening Pinion Bearing Cup Mounting Bolt
Courtesy of FORD MOTOR CO.
Make sure the cups are correctly seated in their bores.
- If a feeler gauge of the specification shown in the illustration below can be inserted between a cup and the bottom of its bore at any point around the cup, the cup is not correctly seated.
  
  Fig 3: Measuring Drive Pinion Bearing Cup Gap
  Courtesy 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.

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	205-937	Drive Pinion Depth Gauge/Aligner
8	4010	Rear axle housing
9	205-281	Handle (T88T-4020-B)

Fig 4: Identifying Adapter, Drive Pinion Depth Gauge, Gauge Block Adapter, Gauge Tube And Pinion Depth Gauge

Courtesy of FORD MOTOR CO.

NOTE: This step duplicates final pinion bearing preload.

Tighten the Adapter to achieve the specified rotational torque.
- Tighten to 2.2 Nm (20 lb-in).
  
  Fig 5: Tightening Adapter With Specified Rotational Torque
  Courtesy of FORD MOTOR CO.
NOTE: The Adapter must be offset to obtain an accurate reading.

Rotate the Adapter several half-turns to make sure of correct seating of the pinion bearings, and position the Adapter.

Fig 6: Adjusting Pinion Bearing Adapter On Seating Position
Courtesy of FORD MOTOR CO.
Install the Gauge Tube.
1. Position the Gauge Tube.
2. Install the 2 differential bearing caps.
3. Install the 4 differential bearing cap bolts.
  - Tighten to 118 Nm (87 lb-ft).
    
    Fig 7: Installing Differential Side Bearing Caps And Bolts
    Courtesy 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.

Use a drive pinion bearing adjustment shim as a gauge for shim selection.

Fig 8: Locating Drive Pinion Bearing Adjustment Shim
Courtesy 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.

For early build vehicles, place the selected shim on the pinion and using the correct tool(s) press the bearing until it is firmly seated on the shaft using the Bearing/Oil Seal Plate and Drive Pinion Bearing Installer.

Fig 9: Installing Pinion Bearing
Courtesy 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.

For late build vehicles, place the selected shim on the pinion and using the correct tool(s) press the bearing until it is firmly seated on the shaft using the Bearing/Oil Seal Plate and Drive Pinion Bearing Installer.

Fig 10: Installing Pinion Bearing
Courtesy of FORD MOTOR CO.
Place a new collapsible spacer on the pinion shaft against the pinion stem shoulder.

Fig 11: Locating Drive Pinion Collapsible Spacer
Courtesy of FORD MOTOR CO.
Install the outer drive pinion bearing and drive pinion shaft oil slinger.

Fig 12: Locating Outer Drive Pinion Bearing And Drive Pinion Shaft Oil Slinger
Courtesy of FORD MOTOR CO.
Lubricate the lip of the new drive pinion seal with grease.
Using the Drive Pinion Oil Seal Installer, install the drive pinion oil seal.

Fig 13: Installing Drive Pinion Oil Seal Using Drive Pinion Oil Seal Installer
Courtesy of FORD MOTOR CO.
Install the drive pinion in the drive pinion carrier bore from inside the rear axle housing.

Fig 14: Installing Drive Pinion Assembly Into Axle Housing
Courtesy of FORD MOTOR CO.
NOTE: The Drive Pinion Flange Installer must be used due to tight spline fit.

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.

Fig 15: Installing Pinion Flange Using Special Tools
Courtesy of FORD MOTOR CO.
Position the new pinion nut and washer.

Fig 16: Locating Pinion Nut And Washer
Courtesy 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.

Use the Drive Pinion Flange Holding Fixture to hold the pinion flange while tightening the pinion nut.
- Tighten the pinion nut, rotating the pinion 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. The final readings must be 0.56 Nm (5 lb-in) more than the initial reading taken during removal.
- After the torque reading is correct, using a round tip centerpunch, stake the pinion nut.
  
  Fig 17: Holding Pinion Flange Using Drive Pinion Flange Holding Fixture
  Courtesy of FORD MOTOR CO.
Fig 18: Locating Pinion Nut Staking Positions
Courtesy of FORD MOTOR CO.
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.
  
  Fig 19: Installing Differential Ring Gear
  Courtesy of FORD MOTOR CO.
Install the remaining 9 new differential ring gear bolts.
- Tighten to 63 Nm (46 lb-ft) and then tighten an additional 60 degrees.
  
  Fig 20: Locating Differential Ring Gear Bolts
  Courtesy of FORD MOTOR CO.
Position the differential case in the rear axle housing.
- Install a shim on the left side as shown in the illustration below.
  
  Fig 21: Identifying Left Side Shim
  Courtesy 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.

Install the left bearing cap and loosely install the 2 bearing cap bolts.

Fig 22: Locating Bearing Cap Mounting Bolts
Courtesy of FORD MOTOR CO.
Install progressively larger shims on the right side until the largest shim selected can be assembled by hand.

Fig 23: Locating Right Side Shim
Courtesy of FORD MOTOR CO.
Install the right side bearing cap with 2 bolts and tighten the 4 bolts.
- Tighten to 118 Nm (87 lb-ft).
  
  Fig 24: Locating Differential Bearing Cap Bolts
  Courtesy of FORD MOTOR CO.
Rotate the differential case to make sure it rotates freely.

Fig 25: Rotating Differential Case
Courtesy of FORD MOTOR CO.
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.
  
  Fig 26: Measuring Ring Gear Backlash Using Dial Indicator Gauge
  Courtesy of FORD MOTOR CO.
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.

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.

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

Fig 27: Locating Differential Bearing Shims

Courtesy of FORD MOTOR CO.

Install the 2 bearing caps and 4 bearing cap bolts.
- Tighten to 118 Nm (87 lb-ft).
  
  Fig 28: Locating Differential Bearing Cap Bolts
  Courtesy of FORD MOTOR CO.
Rotate the differential several times to make sure the differential bearings are correctly seated.

Fig 29: Rotating Differential Case
Courtesy of FORD MOTOR CO.
Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, recheck the backlash.

Fig 30: Measuring Ring Gear Backlash Using Dial Indicator Gauge
Courtesy of FORD MOTOR CO.
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 below.
- Using the Differential Shim Installer, make sure the differential bearing shims are fully seated and the assembly turns freely.
  
  Fig 31: Tapping Differential Bearing Shims
  Courtesy of FORD MOTOR CO.
Install the 2 bearing caps and 4 bearing cap bolts.
- Tighten to 118 Nm (87 lb-ft).
  
  Fig 32: Locating Differential Bearing Cap Bolts
  Courtesy of FORD MOTOR CO.
Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, verify the backlash.

Fig 33: Measuring Ring Gear Backlash Using Dial Indicator Gauge
Courtesy of FORD MOTOR CO.
Apply marking compound and rotate the differential assembly 5 complete revolutions.
Verify an acceptable pattern check. For additional information, refer to DRIVELINE SYSTEM - GENERAL INFORMATION .
Install the axle shafts. For additional information, refer to WHEEL HUBS AND BEARINGS - FULL FLOATING AXLE - FORD .
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. The inside of the rear axle must be covered when cleaning the machined surface to prevent contamination.

Clean the gasket mating surface of the rear axle and the differential housing cover.
Apply a new, continuous bead of silicone to the differential housing cover as shown below.

Fig 34: Locating Continuous Bead Applying Area On Differential Housing Cover
Courtesy 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 has properly cured.

Install the differential housing cover and the 12 differential housing cover bolts.
- For stamped steel housing covers, tighten alternately and evenly to 45 Nm (33 lb-ft).
- For cast aluminum housing covers, tighten alternately and evenly to 32 Nm (24 lb-ft).
  
  Fig 35: Locating Differential Housing Cover Mounting Bolts
  Courtesy of FORD MOTOR CO.
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.

Remove the filler plug, fill the axle to the level shown below with axle lubricant and install the filler plug.
- Tighten to 30 Nm (22 lb-ft).
  
  Fig 36: Identifying Axle Lubricant Fill Level
  Courtesy of FORD MOTOR CO.
Position the driveshaft flange and align the index mark on the pinion flange.

Fig 37: Aligning Index Mark On Pinion Flange
Courtesy 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.

Install the 4 new driveshaft flange bolts.
- Tighten to 103 Nm (76 lb-ft).
  
  Fig 38: Locating Driveshaft Flange Bolt
  Courtesy of FORD MOTOR CO.