Differential Bearings: Installation

WARNING: This page is about a different car, the 2013 Ford Mustang. However, it is still accessible from the selected car via links, so may be relevant.

Position the Drive Pinion Bearing Cup Installer and the new inner and outer drive pinion bearing cups in their respective bores.
1. After placing the inner and outer drive pinion bearing cups in their bores, place the Drive Pinion Bearing Cup Installer (inner) on the inner drive pinion bearing cup.
2. Place the Drive Pinion Bearing Cup Installer (outer) on the outer drive pinion bearing cup.
3. Install the Drive Pinion Bearing Cup Installer threaded rod.
  
  Fig 1: Installing Drive Pinion Bearing Cup Installer Threaded Rod
  Courtesy of FORD MOTOR CO.
Tighten the Drive Pinion Bearing Cup Installer to seat the drive pinion bearing cups into their bores.

Fig 2: Tightening Drive Pinion Bearing Cup Installer Using Special Tool
Courtesy of FORD MOTOR CO.
NOTE: If a feeler gauge can be inserted between a drive pinion bearing cup and the bottom of its bore at any point around the drive pinion bearing cup, the drive pinion bearing cup is not correctly seated.

Make sure the drive pinion bearing cups are correctly seated in their bores.

Fig 3: Checking Drive Pinion Bearing Cups Position Using Special Tool
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 Adapters for 205-S127.

Fig 4: Identifying Special Tools

Courtesy of FORD MOTOR CO.

Item	Part Number	Description
1	205-105	Adapter for 205-S127 (1.612 inch OD) (T76P-4020-A3)
2	205-111	Adapter for 205-S127 (T76P-4020-A11)
3	4621	Drive pinion bearing (outer)
4	205-109	Adapter for 205-S127 (T76P-4020-A9)
5	4630	Drive pinion bearing (inner)
6	205-129	Adapter for 205-S127 (1.1884 inch thick) (T79P-4020-A18)
7	205-110	Adapter for 205-S127 (1.7 inch thick) (T76P-4020-A10)

NOTE: This step duplicates final drive pinion bearing preload.

Tighten the Adapter.
- Tighten to 2.2 Nm (20 lb-in).
  
  Fig 5: Tightening Adapter
  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 drive pinion bearings.

Fig 6: Rotating Adapter
Courtesy of FORD MOTOR CO.
Install the Adapter.
1. Position the Adapter.
2. Install the 2 differential bearing caps.
3. Install the 4 differential bearing cap bolts.
  - Tighten to 122 Nm (90 lb-ft).
    
    Fig 7: Installing Differential Bearing Cap And Bolts Using Special Tool
    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 drive pinion bearing adjustment shim selection. Do not attempt to force the drive pinion bearing adjustment shim between the gauge block and the Adapter. 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.

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 Adapters.
  
  Fig 8: Locating Drive Pinion Bearing Adjustment Shim
  Courtesy of FORD MOTOR CO.
Using the Shaft Bearing Cone Installer and Bearing/Oil Seal Plate, press the inner drive pinion bearing and drive pinion bearing adjustment shim until it is firmly seated on the pinion shaft.

Fig 9: Pressing Inner Drive Pinion Bearing Using Shaft Bearing Cone Installer
Courtesy of FORD MOTOR CO.
Install a new drive pinion collapsible spacer on the pinion shaft against the pinion shaft shoulder.

Fig 10: Locating Drive Pinion Collapsible Spacer On Pinion Shaft
Courtesy of FORD MOTOR CO.
Position the drive pinion assembly into the axle housing.

Fig 11: Positioning Drive Pinion Assembly Into Axle Housing
Courtesy of FORD MOTOR CO.
Install the outer drive pinion bearing and the drive pinion shaft oil slinger.

Fig 12: Locating Outer Drive Pinion Bearing And Drive Pinion Shaft Oil Slinger
Courtesy of FORD MOTOR CO.
Install the drive pinion seal and flange. For additional information, refer to DRIVE PINION FLANGE AND DRIVE PINION SEAL .
Using the Differential Side Bearing Installer, install the 2 new differential bearings.

Fig 13: Installing Differential Bearings On Differential Case Using Bearing Installer
Courtesy of FORD MOTOR CO.
Install the differential carrier. For additional information, refer to DIFFERENTIAL CARRIER .