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 inner and new outer drive pinion bearing cups. Use Special Service Tool: 205-098 (T75T-1176-A) Drawbar, Rear Axle., 205-231 (T85T-4616-AH) Installer, Drive Pinion Bearing., 308-391 Installer, Input Shaft Bearing Cup.

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NOTE: This step duplicates final drive pinion bearing preload

Assemble the special tools in the differential housing. 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)., 205-423 Depth Gauge, Drive Pinion (10 1/2)., 205-937 Adapter, Pinion Aligning.

Torque:

Stage 1: Tighten too: 19 lb.in (2.2 Nm)

Stage 2: Record rotational torque: 3turn(s)

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Check for proper location of special tools.

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Position the tool and install the differential bearing caps and differential bearing cap bolts. Use Special Service Tool: 205-D038 (D81T-4020-F51) Gauge Tube.
Torque: 87 lb.ft (118 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.

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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-D038 (D81T-4020-F51) Gauge Tube.

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Remove the special tools. 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)., 205-423 Depth Gauge, Drive Pinion (10 1/2)., 205-937 Adapter, Pinion Aligning.

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Install the selected inner drive pinion bearing shim.

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Install the new drive pinion inner bearing until it is firmly seated on the drive pinion. Use Special Service Tool: 205-232 (T85T-4621-AH) Installer, Drive Pinion Bearing. Use the General Equipment: Hydraulic Press

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Install the new drive pinion collapsible spacer.

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

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

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NOTE: When installing the drive pinion flange and pinion nut with no differential carrier installed, the drag torque (torque to turn) should be 2 to 3 Nm (16-29 in-lbs).

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