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Differential Ring Gear and Pinion: Installation

WARNING: This page is about a different car, the 2018 Ford F-550 Super Duty, 2018 Ford F-450 Super Duty, 2018 Ford F-350 Super Duty, and 2018 Ford F-250 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the ring gear onto the differential carrier. Align the ring gear using 3 new bolts. Using the general equipment: press the ring gear into place.

    Use the General Equipment: Hydraulic Press

    GFD208249Courtesy of FORD MOTOR COMPANY
  2. Install the remaining new ring gear bolts.

    Torque: 159 lb.ft (215 Nm)

    GFD208250Courtesy of FORD MOTOR COMPANY
  3. Clean and inspect the differential inner oil seal surface.
    GFD208344Courtesy of FORD MOTOR COMPANY
  4. NOTE: To ease installation, coat the seal axle tube mating surfaces with lubricant.
    NOTE: The inner axle shaft oil seals are installed with the black rubber lip towards the center of the axle housing.

    Using the special tools, install the axle shaft oil seals.

    • Place the axle shaft oil seals onto the Installers and position the assembly into the differential housing. Lengthen the Spreader Bar as necessary until both seals start evenly in the axle tubes. Continue to lengthen the tool until both step plates bottom out against the housing.

      Use Special Service Tool: 205-424 Installer, RH Differential Carrier Oil Seal (Dana 50), 205-425 Installer, Differential Carrier Seal LH, 205-428 Spreader Bar, Oil Seal.

    GFD208345Courtesy of FORD MOTOR COMPANY
  5. Place the Dummy Bearing Set on the differential case hubs and position the assembly into the differential housing.

    Use Special Service Tool: 205-D047 (D81T-4222-DR) Set, Dummy Bearing.

    GFD208312Courtesy of FORD MOTOR COMPANY
  6. NOTE: Repeat this step until there is a consistent reading.

    Force the differential case as far as possible toward the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge. With force applied, set the Dial Indicator Gauge at 0. Force the differential case as far as it will go in the opposite direction. Record the total differential case end play reading.

    Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge, 308-021 (T75L-4201-A) Gauge, Clutch Housing, 205-D047 (D81T-4222-DR) Set, Dummy Bearing.

    GFD208346Courtesy of FORD MOTOR COMPANY
  7. NOTE: Do not remove the Dummy Bearing Set from the differential case hubs.

    Remove the differential case with the Dummy Bearing Set from the differential housing.

    Use Special Service Tool: 205-D047 (D81T-4222-DR) Set, Dummy Bearing.

    GFD208312Courtesy of FORD MOTOR COMPANY
  8. If removed, install the new drive pinion oil baffle.
    GFD208300Courtesy of FORD MOTOR COMPANY
  9. NOTE: Make sure the drive pinion bearing cups are seated correctly or damage to the components may occur.

    Using the special tools, install the new outer drive pinion bearing cup.

    Use Special Service Tool: 205-153 (T80T-4000-W) Handle, 205-1024 Installer, Outer Pinion Bearing Cup.

    GFD208301Courtesy of FORD MOTOR COMPANY
  10. 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.

    Assemble the special tools using the new outer drive pinion bearing.

    Use Special Service Tool: 205-159 (T80T-4020-F42) Adapter for 205-S156 Pinion Depth Gauge, 205-160 (T80T-4020-F43) Adapter for 205-S156 Pinion Depth Gauge, 205-281 (T88T-4020-B) Depth Gauge/Aligner, Drive Pinion (Handle), 205-1019 Dummy Pinion Bearing, 205-129 (T79P-4020-A18) Disc, Gauge.

    Torque: 19 lb.in (2.2 Nm)

    GFD208302Courtesy of FORD MOTOR COMPANY
    • Tighten special tools and check for clear rotation.

    • NOTE: This step duplicates final drive pinion bearing preload.

      Tighten the special tool to the specified torque.

      Torque: 18 lb.in (2 Nm)

    • Slowly rotate and record the rotational torque readings.

    GFD208303Courtesy of FORD MOTOR COMPANY
  12. Install the special tool, the differential bearing caps and the differential bearing cap bolts.

    Use Special Service Tool: 205-D033 (D80T-4020-F48) Gauge Tube (3.8135).

    Torque: 80 lb.ft (108 Nm)

    GFD208304Courtesy of FORD MOTOR COMPANY
  13. 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.

    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 the special tools.

    GFD208305Courtesy of FORD MOTOR COMPANY
  14. Notice the (+) or (-) etching on the pinion, and adjust the new shim thickness to compensate for the difference of these 2 figures.

    • For example, a pinion etched with m+8 (+3) requires 0.08 mm (0.003 in) less shimming than a pinion etched "0". This means to increase the mounting distance by the amount etched in the pinion, subtract 0.08 mm (0.003 in) from the drive pinion position shim selected for installation. A pinion etched m-8 (-3), requires 0.08 mm (0.003 in) more shimming than a pinion etched "0". In this instance, add 0.08 mm (0.003 in) to the drive pinion position shim selected for installation to decrease the pinion mounting distance by the amount etched in the pinion.

    GFD208306Courtesy of FORD MOTOR COMPANY
  15. NOTE: Make sure the drive pinion bearing cups are seated correctly or damage to the components may occur.

    Using the special tools, install the new inner drive pinion bearing cup and the selected pinion depth shim.

    Use Special Service Tool: 205-098 (T75T-1176-A) Drawbar, Rear Axle, 205-1024 Installer, Outer Pinion Bearing Cup, 205-1028 Installer, Inner Pinion Bearing Cup.

    GFD208307Courtesy of FORD MOTOR COMPANY
  16. Install the drive pinion bearing until it is firmly seated on the drive pinion.

    Use Special Service Tool: 205-090 (T75L-1165-B) Plate, Bearing/Oil Seal, 205-092 (T75L-1165-DA) Installer, Rear Axle Bearing/Oil Seal.

    Use the General Equipment: Hydraulic Press

    GFD208308Courtesy of FORD MOTOR COMPANY
  17. Install the pinion gear.
    GFD208293Courtesy of FORD MOTOR COMPANY
  18. Install the new drive pinion collapsible spacer.
    GFD208309Courtesy of FORD MOTOR COMPANY
  19. Install the outer drive pinion bearing.
    GFD208310Courtesy of FORD MOTOR COMPANY
  20. Install the outer drive pinion oil slinger.
    GFD208311Courtesy of FORD MOTOR COMPANY
  21. Install the drive pinion flange and seal. REFER to: Drive Pinion Flange and Seal .
  22. NOTE: It is necessary to loosely install the bearing caps and bolts to hold the differential in place.

    Position the differential case with the Dummy Bearing Set into the differential housing.

    Use Special Service Tool: 205-D047 (D81T-4222-DR) Set, Dummy Bearing.

    GFD208312Courtesy of FORD MOTOR COMPANY
  23. Loosely install the differential bearing caps.
    GFD208313Courtesy of FORD MOTOR COMPANY
  24. NOTE: Repeat this step until there is a consistent reading.

    Using the Dummy Bearing Set, Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, determine the total thickness of differential bearing shims to install under the differential bearing on the ring gear side of the differential case. Record this measurement, as the shim thickness required for the ring gear side of the differential case.

    • Force the ring gear away from the pinion and zero the Dial Indicator Gauge.

    • Force the ring gear into mesh with the pinion. Rock the ring gear to allow the teeth of the gears to mesh.

    • Record the reading.

    GFD208314Courtesy of FORD MOTOR COMPANY
  25. Remove the differential case and the Dummy Bearing Set from the differential housing.

    • Remove the Dummy Bearing Set from the differential case.

    GFD208315Courtesy of FORD MOTOR COMPANY
  26. Place the required thickness of differential bearing shims on the ring gear side of the differential case. Refer to the measurement recorded, as the shim thickness required for the ring gear side of the differential case.

    • For example, a reading of 1.14 mm (0.045 in), requires that 1.14 mm (0.045 in) shims be placed on the ring gear side of the differential case. For available differential bearing shims. REFER to: SPECIFICATIONS .

    GFD208316Courtesy of FORD MOTOR COMPANY
  27. Using the Differential Carrier Bearing Installer, install the differential bearing.

    Use Special Service Tool: 205-D044 (D81T-4221-A) Installer, Differential Carrier Bearing.

    GFD208317Courtesy of FORD MOTOR COMPANY
  28. Determine the total thickness of differential bearing shims to install under the differential bearing on the drive pinion side of the differential case.

    • Subtract the measurement recorded, as the shim thickness required for the ring gear side of the differential case, from the total case end play measurement taken at the beginning of the assembly procedure. Then, add 0.38 mm (0.015 in) to the total. This is the total amount of differential bearing shims to install under the differential bearing on the drive pinion side of the differential case.

  29. Place the amount of differential bearing shims, as determined by the calculation made in the previous step, on the drive pinion side of the differential case.
    GFD208318Courtesy of FORD MOTOR COMPANY
  30. Using the Differential Carrier Bearing Installer and Step Plate, install the differential bearing.

    • Place the Step Plate under the bearing to protect it during the bearing installation.

      Use Special Service Tool: 205-D012 (D80L-630-1) Step Plate.

    • Using the Differential Carrier Bearing Installer, install the bearing.

      Use Special Service Tool: 205-D044 (D81T-4221-A) Installer, Differential Carrier Bearing.

    GFD208319Courtesy of FORD MOTOR COMPANY
  31. Position the differential bearing cups on the bearings.
    GFD208320Courtesy of FORD MOTOR COMPANY
  32. Position the differential assembly in the axle housing.
    GFD208321Courtesy of FORD MOTOR COMPANY
  33. Install the bearing caps and the bolts.

    Torque: 80 lb.ft (108 Nm)

    GFD208322Courtesy of FORD MOTOR COMPANY
  34. Using the general equipment, measure the backlash at 3 equally spaced points.

    • The backlash must be within the specifications and cannot vary more than 0.05 mm (0.002 in) between points checked.

      Use the General Equipment: Dial Indicator

    • Make the necessary corrections by moving shims from one side of the differential case to the other, until the correct backlash adjustment is achieved.

    • Correct for low backlash by moving the ring gear away from the pinion.

    • Correct for high backlash by moving the ring gear toward the pinion.

    GFD208323Courtesy of FORD MOTOR COMPANY
  35. Apply marking compound and rotate the differential assembly 5 complete revolutions.
  36. Verify an acceptable pattern check. REFER to: Front Drive Axle .
  37. Clean the gasket material from the differential housing and the differential housing cover.
    GFD208324Courtesy of FORD MOTOR COMPANY
  38. Apply a new continuous bead of sealant to the differential housing cover as shown in illustration.

    Material: Motorcraft® Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)

    GFD208325Courtesy of FORD MOTOR COMPANY
  39. Install the differential cover and differential cover bolts.

    Torque: 45 lb.ft (61 Nm)

    GFD208326Courtesy of FORD MOTOR COMPANY
  40. Install the axle shafts and seals. REFER to: Axle Shaft Seal .
  41. Check the front differential fluid level. REFER to: Differential Fluid Level Check .
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