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Drive Pinion: Installation

WARNING: This page is about a different car, the 2003 Mercury Marauder, 2003 Mercury Grand Marquis, and 2003 Ford Crown Victoria. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: This step and the following step show the preferred method for installing the differential drive pinion bearing cups. An alternate method is shown following these two steps.
  1. Position the special tools and the inner and outer differential drive pinion bearing cups in their respective bores.
    1. After placing the inner and outer bearing cups in their bores, place the special tool on the inner bearing cup.
    2. Place the special tool on the outer bearing cup.
    3. Install the special tool into the replacer tools.
      Fig 1: Installing Special Tool Into Replacer Tools
      G01601508Courtesy of FORD MOTOR CO.
  2. Tighten the special tool to seat the differential drive pinion bearing cups into their bores.
    Fig 2: Tightening Special Tool To Seat Differential Drive Pinion Bearing Cup
    G01601509Courtesy of FORD MOTOR CO.
    3. NOTE: This step and the following step are alternate methods for installing the differential drive pinion bearing cups. Carry out these two steps if differential drive pinion bearing cup installation was not done in the previous steps.
    Fig 3: Driving Outer Differential Drive Pinion Bearing Cup Into Differential Housing Using Special Tool
    G01601510Courtesy of FORD MOTOR CO.
  3. Using the special tools, drive the outer differential drive pinion bearing cup into the differential housing.
  4. Using the special tools, drive the inner differential drive pinion bearing cup into the differential housing.
    Fig 4: Driving Inner Differential Drive Pinion Bearing Cup Into Differential Housing Using Special Tool
    G01601511Courtesy of FORD MOTOR CO.
    5. CAUTION: Always install new differential pinion bearings when installing new differential drive pinion bearing cups.
    NOTE: If the feeler gauge can fit between a cup and the bottom of its bore at any point around the cup, remove and reseat the cup.
    Fig 5: Checking Cups Have Seated Correctly In Their Bores
    G01601512Courtesy of FORD MOTOR CO.
  5. Check that the cups have seated correctly in their bores.
    6. NOTE: Apply only a light lubricant film on the differential pinion bearings before assembling the tool.
    Fig 6: Positioning Differential Components
    G01601513Courtesy of FORD MOTOR CO.
  6. Assemble and position the following in the differential housing.
    7. NOTE: This step duplicates final differential pinion bearing preload.
    Fig 7: Tightening Special Tool To Differential Pinion
    G01601514Courtesy of FORD MOTOR CO.
  7. Tighten the special tool to the specification shown.
    8. CAUTION: Offset the special tool to obtain an accurate reading.
    Fig 8: Rotating Special Tool Several Half-Turns To Make Sure Differential Pinion Bearings Seat Correctly
    G01601515Courtesy of FORD MOTOR CO.
  8. Rotate the special tool several half-turns to make sure the differential pinion bearings seat correctly and position the special tool as shown.
  9. Install the special tool.
    1. Position the special tool.
    2. Install the differential bearing caps.
    3. Install the bolts.
      Fig 9: Installing Differential Bearing Caps
      G01601516Courtesy of FORD MOTOR CO.
    10. CAUTION: Use only flat, clean drive pinion bearing adjustment shims.
    CAUTION: Selection of too thick a shim results in a deep tooth contact at final assembly. Do not attempt to force the shim between the Gauge Block and the Gauge Tube. A slight drag indicates correct shim selection.
  10. Use a drive pinion bearing adjustment shim as a gauge for shim selection.
    • After determining the correct shim thickness, remove the special tools.
      Fig 10: Identifying Correct Shim Thickness
      G01601517Courtesy of FORD MOTOR CO.
  11. Position the correct thickness drive pinion bearing adjustment shim and the differential pinion bearing on the drive pinion. Using a suitable press and the special tools, press the differential pinion bearing until it seats firmly on the pinion.
    Fig 11: Adjusting Shim And Differential Pinion Bearing On Drive Pinion
    G01601518Courtesy of FORD MOTOR CO.
  12. Place a new differential drive pinion collapsible spacer on the pinion shaft against the pinion stem shoulder.
    Fig 12: Placing New Differential Drive Pinion Collapsible Spacer On Pinion Shaft
    G01601519Courtesy of FORD MOTOR CO.
    13. CAUTION: Installation without the correct tool can result in early seal failure.
  13. Install a new rear axle drive pinion seal.
    1. Install the front differential pinion bearing.
    2. Install the rear axle drive pinion shaft oil slinger.
    3. Position the rear axle drive pinion seal on the special tool.
      Fig 13: Positioning Rear Axle Drive Pinion Seal On Special Tool
      G01601520Courtesy of FORD MOTOR CO.
    14. CAUTION: If the rear axle drive pinion seal becomes misaligned during installation, remove the seal and install a new seal.
    NOTE: Coat the rear axle drive pinion seal lips with grease.
    Fig 14: Positioning Rear Axle Drive Pinion Seal In Seal Bore
    G01601521Courtesy of FORD MOTOR CO.
  14. Position the rear axle drive pinion seal in the seal bore, and use the special tool to drive the seal into place.
  15. From inside the differential housing, install the drive pinion assembly (drive pinion, shims, bearing and the collapsible spacer) into the carrier bore.
    Fig 15: Installing Drive Pinion Assembly
    G01601522Courtesy of FORD MOTOR CO.
  16. Lubricate the pinion flange splines with rear axle lubricant.
    17. NOTE: Disregard the index marks if installing a new pinion flange.
    Fig 16: Positioning Pinion Flange
    G01601523Courtesy of FORD MOTOR CO.
  17. Position the pinion flange.
  18. Using the special tool, install the pinion flange.
    Fig 17: Installing Pinion Flange
    G01601524Courtesy of FORD MOTOR CO.
  19. Position the new nut.
    Fig 18: Positioning Pinion Flange New Nut
    G01601525Courtesy of FORD MOTOR CO.
    20. CAUTION: Do not, under any circumstance, loosen the nut to reduce preload. If it is necessary to reduce preload, install a new collapsible spacer and nut.
    CAUTION: Remove the special tool while taking preload readings with the Nm (inch-pound) torque wrench.
  20. Use the special tool to hold the pinion flange while tightening the nut.
    • Rotate the pinion occasionally to make sure the differential pinion bearings seat correctly. Take frequent differential pinion bearing preload readings by rotating the pinion with a Nm (inch-pound) torque wrench.
    • For new differential pinion bearings, tighten the nut to specification. Refer to TORQUE SPECIFICATIONS  for new differential pinion bearings in the Specifications.
    • For used differential pinion bearings, if the preload recorded prior to disassembly is lower than the specification for used bearings, tighten the nut to specification. Refer to TORQUE SPECIFICATIONS  for used differential pinion bearings in the Specifications.
    • For used differential pinion bearings, if the preload recorded prior to disassembly is higher than the specification for used bearings, tighten the nut to the original reading as recorded.
      Fig 19: Tightening Pinion Flange New Nut
      G01601526Courtesy of FORD MOTOR CO.
  21. Place the differential assembly in the differential housing.
  22. Install the bearing shims in the same location as when removed.
  23. Install the bearing caps in their identified locations and tighten the bolts to specification.
    Fig 20: Identifying Bearing Caps
    G01601527Courtesy of FORD MOTOR CO.
  24. Rotate the differential case to make sure it turns freely.
    Fig 21: Rotating Differential Case To Make Sure It Turns Freely
    G01601528Courtesy of FORD MOTOR CO.
  25. Using the special tools, measure differential ring gear backlash. For additional information, refer to DIFFERENTIAL CASE .
    Fig 22: Measuring Differential Ring Gear Backlash Using Special Tool
    G01601529Courtesy of FORD MOTOR CO.
    26. CAUTION: Align the index marks.
    CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion flange pilot. To make sure that the yoke seats squarely on the flange, tighten the bolts evenly in a cross pattern as shown.
    Fig 23: Installing Driveshaft
    G01601530Courtesy of FORD MOTOR CO.
  26. Install the driveshaft.
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