Drive Pinion: Assembly

Initial assembly 

1. Using a suitable driver, press the inner pinion bearing onto the pinion.
Fig 1: Pressing Inner Pinion Bearing Onto Pinion
Courtesy of FORD MOTOR CO.
2. Press the inner and outer pinion bearing cups into the carrier until seated.
   • Use a 0.0381 mm (0.0015 in) feeler gauge to verify the bearing cups have completely seated in the bearing bores.
   • Lubricate the bearing cups and cone.
Fig 2: Identifying Outer And Inner Pinion Bearing Cups
Courtesy of FORD MOTOR CO.
3. Seat the outer pinion bearing on the pinion.
   1. Seat the inner pinion bearing into the cup by positioning a 152.4 x 152.4 x 152.4 mm (6 x 6 x 6 in) block of wood under the pinion.
   2. Place the original pinion preload spacer onto the pinion.
   3. Place the outer pinion bearing onto the pinion.
   4. Using a suitable press, seat the outer bearing on the pinion.
Fig 3: Seating Outer Pinion Bearing On Pinion
Courtesy of FORD MOTOR CO.
NOTE: Do not install the pinion seal at this time.
4. Install the pinion flange.
5. Install the hex nut.
   • Using a suitable torque multiplier, tighten to 1128 Nm (832 lb-ft).
Fig 4: Locating Hex Nut
Courtesy of FORD MOTOR CO.

Measuring pinion bearing preload torque 

6. Measure the torque to rotate.
   • Take torque measurements every fourth revolution.
   • Proceed to Pinion bearing preload adjustment in this procedure if the bearing preload torque is not within the specifications. Proceed to Final assembly in this procedure if the bearing preload torque is within the specifications.
Fig 5: Measuring Pinion Bearing Preload With Specifications
Courtesy of FORD MOTOR CO.

Pinion bearing preload adjustment 

NOTE: Also refer to the following illustration.
7. Adjust the pinion bearing preload by installing a new pinion bearing preload spacer.
   • To increase the preload, install a thinner spacer. To decrease the preload, install a thicker spacer.
   • The pinion bearing preload spacers are available in sizes from 7.26 to 8.00 mm (0.286 to 0.315 in).
   • Always measure the new spacer before installing it.
   • On a flat surface, sand the next thicker size spacer with an emery cloth to the required thickness to obtain a closer adjustment. Thoroughly wash the spacer to remove the emery cuttings before installation.
   • A 0.0254 mm (0.001 in) change in the spacer thickness will change the torque rate approximately 3.3894 N.m (30 lb-in).
   • Repeat Measuring pinion bearing preload torque and Pinion bearing preload adjustment in this procedure until the rotational torque is within specifications.
Fig 6: Installing Pinion Bearing Preload Spacer
Courtesy of FORD MOTOR CO.
Fig 7: Measuring Pinion Bearing Preload With Specifications
Courtesy of FORD MOTOR CO.

Final assembly 

8. Using a suitable torque multiplier, remove the hex nut.
Fig 8: Pinion Nut
Courtesy of FORD MOTOR CO.
NOTE: Hammering on the pinion flange will close in the bearing bores and misalign the flange lugs. This will result in premature failure of the journal needle bearings. Serious damage will also occur internally to the differential ring gear and pinion or pinion bearings by hammering on external parts. Remove and install the pinion flange using only the procedures.
9. Using the Yoke Remover, remove the pinion flange.
Fig 9: Identifying Special Tool (205-443) & Pinion Flange
Courtesy of FORD MOTOR CO.
10. Using a suitable tool, install the pinion seal.
    • A rotational torque of 1.6947-5.0841 N.m (15-45 lb-in) is acceptable with the pinion seal installed.
11. Install the pinion flange.
12. Apply stud and bearing mount to the pinion threads, and install a new hex nut.
    • Using a suitable torque multiplier, tighten to 1128 Nm (832 lb-ft).
Fig 10: Locating Hex Nut
Courtesy of FORD MOTOR CO.
13. Assemble the carrier. For additional information, refer to Differential Case and Ring Gear .