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Differential Ring Gear and Pinion: Installation

WARNING: This page is about a different car, the 2019 Ford F-550 Super Duty, 2019 Ford F-450 Super Duty, 2019 Ford F-350 Super Duty, and 2019 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
    GFD405136Courtesy of FORD MOTOR COMPANY
  2. Install the remaining new ring gear bolts.

    Torque: 159 lb.ft (215 Nm)

    GFD405137Courtesy of FORD MOTOR COMPANY
  3. Clean and inspect the differential inner oil seal surface.
    GFD405217Courtesy 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.

    GFD405218Courtesy 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.
    GFD405150Courtesy 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.

    GFD405219Courtesy 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.

    GFD405150Courtesy of FORD MOTOR COMPANY
  8. If removed, install the new drive pinion oil baffle.
    GFD405195Courtesy 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.

    GFD404905Courtesy 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, Guage.

    Torque: 19 lb.in (2.2 Nm)

    GFD405196Courtesy 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.

    GFD404907Courtesy 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)

    GFD405197Courtesy 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.

    GFD404996Courtesy of FORD MOTOR COMPANY
  14. 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. Use Special Service Tool: 205-098 (T75T-1176-A) Drawbar, Rear Axle., 205-1024 Installer, Outer Pinion Bearing Cup., 205-1023 Installer, Inner Pinion Bearing Cup.

    GFD405199Courtesy of FORD MOTOR COMPANY
  15. 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
    GFD405200Courtesy of FORD MOTOR COMPANY
  16. Install the pinion gear.
    GFD405190Courtesy of FORD MOTOR COMPANY
  17. Install the new drive pinion collapsible spacer.
    GFD405201Courtesy of FORD MOTOR COMPANY
  18. Install the outer drive pinion bearing.
    GFD405202Courtesy of FORD MOTOR COMPANY
  19. Install the outer drive pinion oil slinger.
    GFD405203Courtesy of FORD MOTOR COMPANY
  20. Install the drive pinion flange and seal. Refer to: Drive Pinion Flange and Seal .
  21. 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.

    GFD405150Courtesy of FORD MOTOR COMPANY
  22. Loosely install the differential bearing caps.
    GFD405151Courtesy of FORD MOTOR COMPANY
  23. 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.

    GFD405152Courtesy of FORD MOTOR COMPANY
  24. Remove the differential case and the Dummy Bearing Set from the differential housing.

    • Remove the Dummy Bearing Set from the differential case.

    GFD405146Courtesy of FORD MOTOR COMPANY
  25. 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 .

    GFD405153Courtesy of FORD MOTOR COMPANY
  26. Using a special tool, install the differential bearing. Use Special Service Tool: 205-D044 (D81T-4221-A) Installer, Differential Carrier Bearing.
    GFD405154Courtesy of FORD MOTOR COMPANY
  27. 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.

  28. 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.
    GFD405155Courtesy of FORD MOTOR COMPANY
  29. Using the special tools, 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.

    GFD405156Courtesy of FORD MOTOR COMPANY
  30. Position the differential bearing cups on the bearings.
    GFD405157Courtesy of FORD MOTOR COMPANY
  31. Position the differential carrier and bearing races along with shims in the axle housing.
    GFD405158Courtesy of FORD MOTOR COMPANY
  32. Install the bearing caps and the bolts.

    Torque: 80 lb.ft (108 Nm)

    GFD405204Courtesy of FORD MOTOR COMPANY
  33. 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. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.

    GFD405152Courtesy of FORD MOTOR COMPANY
  34. Apply marking compound and rotate the differential assembly 5 complete revolutions.
  35. Verify an acceptable pattern check. Refer to: Front Drive Axle .
  36. Clean the gasket material from the differential housing and the differential housing cover. Refer to: RTV Sealing Surface Cleaning and Preparation .
    GFD405143Courtesy of FORD MOTOR COMPANY
  37. Apply a new continuous bead of sealant to the differential housing cover as shown.

    Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

    GFD405160Courtesy of FORD MOTOR COMPANY
  38. Install the differential cover and differential cover bolts.

    Torque: 45 lb.ft (61 Nm)

    GFD405142Courtesy of FORD MOTOR COMPANY
  39. Attach the RH outer tie rod end and drag link to the wheel knuckle and install the new tie rod end nut.

    Torque: 85 lb.ft (115 Nm)

    GFD404648Courtesy of FORD MOTOR COMPANY
    1. Install the sector shaft arm drag link nut retainer.
    2. NOTE: Make sure that the new component is used.

      Install the new sector shaft arm drag link cotter pin.

    GFD405220Courtesy of FORD MOTOR COMPANY
  41. Install the axle shaft seal. Refer to: Axle Shaft Seal .
  42. Check the front differential fluid level. Refer to: Differential Fluid Level Check .
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