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Home >> Mercury >> 2009 >> Mariner Base, 2.5 7, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 23 (Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear) >> In-Vehicle Servicing >> Differential Ring And Pinion >> Installation

Differential Ring And Pinion: Installation

WARNING: This page is about a different car, the 2009 Ford Mustang. However, it is still accessible from the selected car via links, so may be relevant.
  1. Position the special tool and the inner and outer drive pinion bearing cups in their respective bores.
    1. After placing the inner and outer drive pinion bearing cups in their bores, place the special tool (inner) on the inner drive pinion bearing cup.
    2. Place the special tool (outer) on the outer drive pinion bearing cup.
    3. Install the special tool.
    2. Fig 1: Identifying Special Tool (205-024) Components
    G03878597Courtesy of FORD MOTOR CO.
  2. Tighten the special tool to seat the drive pinion bearing cups into their bores.
    3. Fig 2: Identifying Special Tool (205-024) To Seat Pinion Bearing Cups
    G03878598Courtesy of FORD MOTOR CO.
    NOTE: If a feeler gauge can be inserted between a drive pinion bearing cup and the bottom of its bore at any point around the drive pinion bearing cup, the drive pinion bearing cup is not correctly seated.
  3. Make sure the drive pinion bearing cups are correctly seated in their bores.
    4. Fig 3: Measuring Clearance Between Cup And Bottom Of Its Bore
    G03878599Courtesy of FORD MOTOR CO.
    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.
  4. Assemble and position the special tools.
    Item Part Number Description
    1 205-105 Adapter for 205-S127 (1.612 inch O.D.) (T76P-4020-A3)
    2 205-111 Adapter for 205-S127 (T76P-4020-A11)
    3 4621 Drive pinion bearing (outer)
    4 205-109 Adapter for 205-S127 (T76P-4020-A9)
    5 4630 Drive pinion bearing (inner)
    6 205-129 Adapter for 105-S127 (1.1884 inch thick) (T79P-4020-A18)
    7 205-110 Adapter for 205-S127 (1.7 inch thick) (T76P-4020-A10)
    5. Fig 4: Identifying Drive Pinion Depth Gauge Set
    GF0003082Courtesy of FORD MOTOR CO.
    NOTE: This step duplicates final drive pinion bearing preload.
  5. Tighten the special tool.
    • Tighten to 2.2 Nm (20 lb-in).
    6. Fig 5: Checking Differential Pinion Bearing Preload
    G03878601Courtesy of FORD MOTOR CO.
    NOTE: The special tool must be offset to obtain an accurate reading.
  6. Rotate the special tool several half-turns to make sure of correct seating of the drive pinion bearings and position the special tool.
    7. Fig 6: Rotating Gauge Block For Correct Seating Of Drive Pinion Bearings
    G03878602Courtesy of FORD MOTOR CO.
  7. Install the special tool.
    1. Position the special tool.
    2. Install the 2 differential bearing caps.
    3. Install the 4 differential bearing cap bolts.
      • Tighten to 105 Nm (77 lb-ft).
    8. Fig 7: Identifying Special Tool (205-130)
    G03878603Courtesy of FORD MOTOR CO.
    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.
  8. 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 all of the special tools.
    9. Fig 8: Identifying Drive Pinion Bearing Adjustment Shim
    GF0000838Courtesy of FORD MOTOR CO.
  9. Using the special tool and a shop press, drive the inner drive pinion bearing and the selected drive pinion bearing adjustment shim until they are firmly seated on the pinion shaft.
    10. Fig 9: Locating Inner Drive Pinion Bearing
    G03878605Courtesy of FORD MOTOR CO.
  10. Install a new drive pinion collapsible spacer on the pinion shaft against the pinion shaft shoulder.
    11. Fig 10: Identifying Drive Pinion Collapsible Spacer
    GF0000836Courtesy of FORD MOTOR CO.
  11. Install the drive pinion assembly into the axle housing.
    12. Fig 11: Locating Drive Pinion Gear
    GF0000840Courtesy of FORD MOTOR CO.
  12. Install the outer drive pinion bearing and the drive pinion shaft oil slinger.
  13. Using the special tools, install the drive pinion seal.
    14. Fig 12: Using Special Tool (205-208) To Install Drive Pinion Seal
    G03878608Courtesy of FORD MOTOR CO.
  14. Using the special tools, install the drive pinion flange.
    15. Fig 13: Installing Drive Pinion Flange Using Special Tools 205-126 & 205-002
    GF0015355Courtesy of FORD MOTOR CO.
    NOTE: Do not, under any circumstance, loosen the drive pinion nut to reduce pinion bearing preload. If it is necessary to reduce the preload, install a new drive pinion collapsible spacer and drive pinion nut.
    NOTE: Remove the special tool while taking rotational pinion bearing preload checks with the Nm (lb-in) torque wrench.
  15. Use the special tool to hold the pinion flange while tightening the pinion nut.
    • Rotate the pinion occasionally to make sure the differential pinion bearings are seating correctly. Take frequent differential pinion bearing preload checks by rotating the differential pinion with a Nm (lb-in) torque wrench. Tighten the pinion nut in small increments to avoid excessive pinion bearing preload. Tighten the pinion nut until the drive pinion bearing preload is in specification.
    16. Fig 14: Installing Drive Pinion Flange Using Special Tools 205-126 & 205-002
    GF0015355Courtesy of FORD MOTOR CO.
  16. Using the special tool, install the 2 new differential bearings.
    17. Fig 15: Installing Differential Bearings On Differential Case
    G03878611Courtesy of FORD MOTOR CO.
  17. Install the 10 new differential ring gear bolts.
    • Tighten to 105 Nm (77 lb-ft).
    18. Fig 16: Identifying Differential Ring Gear Bolts
    G03878612Courtesy of FORD MOTOR CO.
  18. Position the differential carrier assembly and the 2 new differential bearing cups in the differential housing.
    19. Fig 17: Identifying Differential Carrier Assembly
    GF0015356Courtesy of FORD MOTOR CO.
  19. Install a differential bearing shim of the shown dimension on the left side.
    20. Fig 18: Identifying Differential Bearing Shim
    GF0015357Courtesy of FORD MOTOR CO.
    NOTE: Always install the bearing caps in their original locations and positions.
    NOTE: Apply pressure toward the LH side to make sure the left differential bearing cup seats correctly.
  20. Install the LH bearing cap and loosely install the 2 bolts.
    21. Fig 19: Locating LH Bearing Cap & Bolts
    GF0015358Courtesy of FORD MOTOR CO.
  21. Install progressively larger differential bearing shims on the RH side until the largest shim is installed by hand.
    22. Fig 20: Identifying Differential Bearing Shim
    GF0000843Courtesy of FORD MOTOR CO.
  22. Install the right side bearing cap and 2 bolts. Tighten the 4 LH and RH bearing cap bolts.
    • Tighten to 105 Nm (77 lb-ft).
  23. Rotate the differential carrier several times to verify the differential bearings have seated correctly.
    24. Fig 21: Rotating Differential Assembly
    GF0000844Courtesy of FORD MOTOR CO.
  24. Install the special tools and measure the ring gear backlash.
    • If the backlash is within specification, proceed to Step 27.
    • If a zero backlash condition occurs, proceed to Step 25.
    • If the backlash is not within specification, proceed to Step 26.
    25. Fig 22: Measuring Ring Gear Backlash
    G03878618Courtesy of FORD MOTOR CO.
  25. If a zero backlash condition occurs, add 0.50 mm (0.020 in) to the RH side shim and subtract 0.50 mm (0.020 in) from the LH side shim to allow a backlash indication. Go back to Step 24.
  26. To correct for high or low backlash, increase the thickness of one differential bearing shim and decrease the thickness of the other differential bearing shim by the same amount. Refer to the following tables when adjusting the backlash. When the backlash is within specification, proceed to Step 27.
    Backlash Change Required Thickness Change Required
    mm Inch mm Inch
    0.025 0.001 0.050 0.002
    0.050 0.002 0.050 0.002
    0.076 0.003 0.101 0.004
    0.101 0.004 0.152 0.006
    0.127 0.005 0.152 0.006
    0.152 0.006 0.203 0.008
    0.177 0.007 0.254 0.010
    0.203 0.008 0.254 0.010
    0.228 0.009 0.304 0.012
    0.254 0.010 0.355 0.014
    0.279 0.011 0.355 0.014
    0.304 0.012 0.406 0.016
    0.330 0.013 0.457 0.018
    0.335 0.014 0.457 0.018
    0.381 0.015 0.508 0.020
    DIFFERENTIAL SHIM SIZE CHART 4067

    Stripes and Color Code Dimension A
    mm Inch
    2 - C-COAL 7.7978-7.8105 0.3070-0.3075
    1 - C-COAL 7.7470-7.7597 0.3050-0.3055
    5 - BLU 7.6962-7.7089 0.3030-0.3035
    4 - BLU 7.6454-7.6581 0.3010-0.3015
    3 - BLU 7.5946-7.6073 0.2990-0.2995
    2 - BLU 7.5458-7.5565 0.2970-0.2975
    5 - PINK 7.4422-7.4549 0.2930-0.2935
    4 - PINK 7.3914-7.4041 0.2910-0.2915
    3 - PINK 7.3406-7.3533 0.2890-0.2895
    2 - PINK 7.2898-7.3025 0.2870-0.2875
    1 - PINK 7.2390-7.2517 0.2850-0.2855
    5 - GRN 7.1882-7.2009 0.2830-0.2835
    4 - GRN 7.1374-7.1501 0.2810-0.2815
    3 - GRN 7.0866-7.0993 0.2790-0.2795
    2 - GRN 7.0358-7.0485 0.2770-0.2775
    1 - GRN 6.9850-7.0485 0.2750-0.2755
    5 - WH 6.9342-6.9469 0.2730-0.2735
    4 - WH 6.8834-6.8961 0.2710-0.2715
    3 - WH 6.8326-6.8453 0.2690-0.2695
    2 - WH 6.7818-6.7945 0.2670-0.2675
    1 - WH 6.7310-6.7437 0.2650-0.2655
    5 - YEL 6.6802-6.6929 0.2630-0.2635
    4 - YEL 6.6294-6.6421 0.2610-0.2615
    3 - YEL 6.5786-6.5913 0.2590-0.2595
    2 - YEL 6.5278-6.5405 0.2570-0.2575
    1 - YEL 6.4770-6.4897 0.2550-0.2555
    5 - ORNG 6.4262-6.4389 0.2530-0.2535
    4 - ORNG 6.3754-6.3881 0.2510-0.2515
    3 - ORNG 6.3246-6.3373 0.2490-0.2495
    2 - ORNG 6.2738-6.2865 0.2470-0.2475
    1 - ORNG 6.2223-6.2357 0.2450-0.2455
    2 - RED 6.1722-6.1849 0.2430-0.2435
    1 - RED 6.1214-6.1341 0.2410-0.2415
  27. Remove the 4 bearing cap bolts and 2 bearing caps.
  28. To establish differential bearing preload, increase both LH and RH differential bearing shim size by the thickness shown.
    29. Fig 23: Identifying Differential Bearing Shim For Preload With Specifications
    G03878619Courtesy of FORD MOTOR CO.
  29. Using the special tool, fully seat the differential bearing shims. Make sure the assembly rotates freely.
    30. Fig 24: Seating Differential Bearing Shims Using Special Tool (205-220)
    G03878620Courtesy of FORD MOTOR CO.
  30. Install the 2 bearing caps and 4 bolts.
    • Tighten to 105 Nm (77 lb-ft).
    31. Fig 25: Locating Bearing Caps & Bolts
    GF0015359Courtesy of FORD MOTOR CO.
  31. Using the special tools, recheck the ring gear backlash.
    32. Fig 26: Checking Differential Ring Gear Backlash
    G03878483Courtesy of FORD MOTOR CO.
  32. Apply marking compound and rotate the differential assembly 5 complete revolutions.
  33. Check for an acceptable pattern.
  34. Install the axle shafts. For additional information, refer to Axle Shaft .
  35. Install the driveshaft. For additional information, refer to DRIVESHAFT .
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