Drive 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.

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.

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NOTE: Only tighten finger tight at this stage.

Assemble the pinion depth special tools and the new outer bearing in the differential housing. Use Special Service Tool: 205-129 (T79P-4020-A18) Disc, Guage., 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)., 205-1026 Dummy Pinion Bearing.

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- 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.
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Install the special tool and the differential bearing caps and differential bearing cap bolts. Use Special Service Tool: 205-1025 Gauge Tube.
Torque:

LH differential bearing cap bolts: 201 lb.ft (272 Nm)

RH differential bearing cap bolts: 102 lb.ft (138 Nm)

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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 the final assembly of integral axle assemblies.

Use a drive pinion bearing adjustment shim as a gauge for drive pinion bearing adjustment shim selection. Select the correct shim that has a slight drag.

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NOTE: The differential bearing caps need to stay in the correct orientation for installation.

Remove the differential bearing cap bolts and differential bearing caps, remove the special tools. Use Special Service Tool: 205-1025 Gauge Tube.

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Remove the special tools and the outer pinion bearing. Use Special Service Tool: 205-129 (T79P-4020-A18) Disc, Guage., 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)., 205-1026 Dummy Pinion Bearing.

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NOTE: Make sure the drive pinion bearing cups are seated correctly or damage to the components may occur.

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

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Install the drive pinion inner bearing until it is firmly seated on the drive pinion. Use Special Service Tool: 205-1038 Installer, Pinion Bearing Head.. Use the General Equipment: Hydraulic Press

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Install the new drive pinion collapsible spacer.

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Install the new outer differential pinion bearing and the differential pinion.

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Install the drive pinion outer thrust washer.

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Install the drive pinion seal. Refer to: Drive Pinion Seal .
Install the differential carrier. Refer to: Differential Carrier .