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Home >> Mercury >> 2009 >> Mariner Base, 2.5 7, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 24 (Rear Drive Axle/Differential - Ford 7.5-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 Drive Pinion Bearing Cup Installer 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 Drive Pinion Bearing Cup Installer (inner) on the inner drive pinion bearing cup.
    2. Place the Drive Pinion Bearing Cup Installer (outer) on the outer drive pinion bearing cup.
    3. Install the Drive Pinion Bearing Cup Installer.
    2. Fig 1: Identifying Special Tool (205-054)
    GF0009734Courtesy of FORD MOTOR CO.
  2. Tighten the Drive Pinion Bearing Cup Installer to seat the drive pinion bearing cups into their bores.
    3. Fig 2: Tightening Special Tool (205-054)
    GF0009735Courtesy 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 Adapters in the sequence shown.
    5. Fig 4: Identifying Special Tools (205-105) And (205-109)
    GF0009736Courtesy of FORD MOTOR CO.
    NOTE: This step duplicates final drive pinion bearing preload.
  5. Tighten the Adapter.
    • Tighten to 2.2 Nm (20 lb-in).
    6. Fig 5: Checking Differential Pinion Bearing Preload
    G03878601Courtesy of FORD MOTOR CO.
    NOTE: The Adapter must be offset to obtain an accurate reading.
  6. Rotate the Adapter several half-turns to make sure of correct seating of the drive pinion bearings and position the Adapter.
    7. Fig 6: Rotating Special Tool (205-110) To Seat Bearings
    GF0009737Courtesy of FORD MOTOR CO.
  7. Install the Gauge Tube.
    1. Position the Gauge Tube.
    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-D034)
    GF0009738Courtesy 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 Adapters.
    9. Fig 8: Identifying Drive Pinion Bearing Adjustment Shim
    GF0000838Courtesy of FORD MOTOR CO.
  9. Using the Drive Pinion Bearing Cone Installer and Bearing/Oil Seal Plate, press the inner drive pinion bearing and drive pinion bearing adjustment shim until it is firmly seated on the pinion shaft.
    10. Fig 9: Identifying Special Tools (205-005) & (205-090)
    GF0009739Courtesy 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 outer drive pinion bearing and the drive pinion shaft oil slinger.
    12. Fig 11: Identifying Outer Drive Pinion Bearing And Drive Pinion Shaft Oil Slinger
    GF0000839Courtesy of FORD MOTOR CO.
  12. Using the Drive Pinion Oil Seal Installer, install the drive pinion seal.
    13. Fig 12: Using Special Tool (205-208) To Install Drive Pinion Seal
    G03878608Courtesy of FORD MOTOR CO.
  13. Position the drive pinion assembly into the axle housing.
    14. Fig 13: Locating Drive Pinion Gear
    GF0000840Courtesy of FORD MOTOR CO.
  14. Using the Drive Pinion Flange Holding Fixture and Drive Pinion Flange Installer, install the drive pinion flange.
    15. Fig 14: Using Special Tools (205-126, 205-002) To Hold Drive Pinion Flange
    G03878609Courtesy of FORD MOTOR CO.
    NOTE: Do not, under any circumstance, loosen the drive pinion nut to reduce pinion bearing preload or damage to the component may occur. If it is necessary to reduce the preload, install a new drive pinion collapsible spacer and drive pinion nut.
    NOTE: Remove the Drive Pinion Flange Holding Fixture while taking rotational pinion bearing preload checks with the Nm (lb-in) torque wrench.
  15. Use the Drive Pinion Flange Holding Fixture 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.
      • Tighten to a rotational torque of 1.8-3.3 Nm (16-29 lb-in).
    16. Fig 15: Using Special Tool (205-126) To Hold Pinion Flange
    G03878610Courtesy of FORD MOTOR CO.
  16. Using the Differential Side Bearing Installer, install the 2 new differential bearings.
    17. Fig 16: Identifying Special Tools (205-009)
    GF0009731Courtesy of FORD MOTOR CO.
  17. Press the differential ring gear on the differential assembly.
    18. Fig 17: Pressing Differential Ring Gear On Differential Case
    GF0000848Courtesy of FORD MOTOR CO.
    NOTE: Apply stud and bearing mount to the new differential ring gear bolts.
  18. Install the 10 new differential ring gear bolts.
    • Tighten to 105 Nm (77 lb-ft).
    19. Fig 18: Identifying Differential Ring Gear Bolts
    G03878612Courtesy of FORD MOTOR CO.
  19. Position the differential carrier assembly and the new differential bearing cups in the differential housing.
    20. Fig 19: Positioning Differential Assembly In Axle Housing
    GF0000841Courtesy of FORD MOTOR CO.
  20. Install a differential bearing shim of the shown dimension on the LH side.
    21. Fig 20: Locating Differential Bearing Shim
    G03878614Courtesy of FORD MOTOR CO.
    NOTE: Always install the bearing caps in their original locations and positions.
    NOTE: Apply pressure toward the left side to make sure the LH differential bearing cup seats correctly.
  21. Install the LH bearing cap and loosely install the 2 bolts.
    22. Fig 21: Identifying LH Differential Bearing Cap And Bolts
    GF0000842Courtesy of FORD MOTOR CO.
  22. Install progressively larger differential bearing shims on the RH side until the largest shim is installed by hand.
    23. Fig 22: Identifying Differential Bearing Shim
    GF0000843Courtesy of FORD MOTOR CO.
  23. 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).
  24. Rotate the differential carrier several times to verify the differential bearings have seated correctly.
    25. Fig 23: Rotating Differential Assembly
    GF0000844Courtesy of FORD MOTOR CO.
  25. Install the Dial Indicator Gauge with Brackets and measure the ring gear backlash.
    • If the backlash is within specification, proceed to Step 28.
    • If a zero backlash condition occurs, proceed to Step 26.
    • If the backlash is not within specification, proceed to Step 27.
    26. Fig 24: Measuring Ring Gear Backlash
    G03878618Courtesy of FORD MOTOR CO.
  26. 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 25.
  27. 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 28.
    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
  28. Remove the 4 bearing cap bolts and 2 bearing caps.
  29. To establish differential bearing preload, increase both LH and RH differential bearing shim size by the thickness shown.
    30. Fig 25: Identifying Differential Bearing Shim For Preload With Specifications
    G03878619Courtesy of FORD MOTOR CO.
  30. Using the Differential Shim Installer, fully seat the differential bearing shims. Make sure the assembly rotates freely.
    31. Fig 26: Seating Differential Bearing Shims Using Special Tool (205-220)
    G03878620Courtesy of FORD MOTOR CO.
  31. Install the 2 bearing caps and 4 bolts.
    • Tighten to 105 Nm (77 lb-ft).
    32. Fig 27: Identifying Differential Bearing Cap And Differential Bearing Cap Bolts
    G03878679Courtesy of FORD MOTOR CO.
  32. Using the Dial Indicator Gauge with Brackets, recheck the ring gear backlash.
    33. Fig 28: Measuring Ring Gear Backlash
    G03878618Courtesy of FORD MOTOR CO.
  33. Apply marking compound and rotate the differential assembly 5 complete revolutions.
  34. Verify an acceptable pattern check.
  35. Install the axle shafts. For additional information, refer to Axle Shaft .
  36. Install the driveshaft. For additional information, refer to DRIVESHAFT .
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