Drive Pinion: Installation

WARNING: This page is about a different car, the 2024 Ford Transit-350 HD, 2024 Ford Transit-350, 2024 Ford Transit-250, and 2024 Ford Transit-150. 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: 205-024 (T67P-4616-A) Installer, Drive Pinion Bearing Cup. 205-852 Inner Pinion Bearing Cup Installer, 308-391 Installer, Input Shaft Bearing Cup.

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NOTE: Only tighten finger tight at this stage.

Assemble the special tools and new bearings in the differential housing. Use Special Service Tool: 205-111 (T76P-4020-A11) Handle, 205-160 (T80T-4020-F43) Adapter for 205-S156 Pinion Depth Gauge, 205-937 Adapter, Pinion Aligning, 205-383 (T97T-4020-B) Depth Gauge/Aligner, Drive Pinion, 205-159 (T80T-4020-F42) Adapter for 205-S156 Pinion Depth Gauge.

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- Install the special tool. Use Special Service Tool: 205-111 (T76P-4020-A11) Handle.
- NOTE: This step duplicates final drive pinion bearing preload
  
  Tighten the special tool to the specified torque.
  
  Torque : 2 Nm
- Slowly rotate and record the rotational torque readings.
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Check for proper location of special tools.

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- Position the special tool. Use Special Service Tool: 205-377 (T97T-4020-A) Gauge Tube, Drive Pinion.
- Install the differential bearing caps and differential bearing cap bolts.
  Torque : 112 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: 205-377 (T97T-4020-A) Gauge Tube, Drive Pinion.

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Remove the special tool. Use Special Service Tool: 205-111 (T76P-4020-A11) Handle.

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Remove the special tools and bearings. Use Special Service Tool: 205-111 (T76P-4020-A11) Handle, 205-160 (T80T-4020-F43) Adapter for 205-S156 Pinion Depth Gauge, 205-937 Adapter, Pinion Aligning, 205-383 (T97T-4020-B) Depth Gauge/Aligner, Drive Pinion, 205-159 (T80T-4020-F42) Adapter for 205-S156 Pinion Depth Gauge.

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Install the drive pinion inner bearing and selected drive pinion bearing adjustment shim until they are firmly seated on the drive pinion. Use Special Service Tool: 205-090 (T75L-1165-B) Plate, Bearing/Oil Seal, 205-488 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 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