Pinion Gear: Service and Repair

Special Tools:

Removal
1. Remove the differential case.

2. Mark the driveshaft flange and the pinion flange for correct alignment during installation.

3. Remove the four driveshaft bolts and disconnect the driveshaft.

4. Install a Nm (inch/pound) torque wrench on the pinion nut and record the torque required to maintain rotation of the pinion through several revolutions.
5. Remove the pinion flange and pinion nut.

6. Install the special tool and, with a soft-faced hammer, drive the pinion assembly out of the front bearing cone and remove it through the rear of the housing.
- Remove the rear axle drive pinion seal.
- Remove the rear axle drive pinion oil slinger.

7. Note: Remove the collapsible spacer and discard it.

Using the special tool, remove the pinion bearing.

8. Note: Do not remove the pinion bearing cups from the carrier casting unless the cups are damaged.

Remove the outer differential bearing cup with the special tools.

9. Remove the inner differential bearing cup with the special tools.

Installation
Using 205-024

1. Position the special tools and the inner and outer bearing cups in their respective bores.
1 After placing the inner and outer bearing cups in their bores, place the special tool (inner) on the inner pinion bearing cup.
2 Place the special tool (outer) on the outer pinion bearing cup.
3 Install the special tool.

2. Tighten the special tool to seat the pinion bearing cups into their bores.

Using 205-024, 20S-153, and 205-DOSS

3. Drive the outer pinion bearing cup into the axle housing using the special tools.

4. Drive the inner pinion bearing cup into the axle housing using the special tools.

Setting pinion depth

5. CAUTION: Whenever the cups are replaced, the pinion bearings must also be replaced.

Note: If a feeler gauge can be inserted between a cup and the bottom of its bore at any point around the cup, the cup is not correctly seated.

Make sure the cups are correctly seated in their bores.

6. Note: Apply only a light oil film on the pinion bearings before assembling the tool.

Assemble and position the special tools.

7. Note: This step duplicates final pinion bearing preload.

Tighten the special tool to the specification.

8. Note: The special tool must be offset to obtain an accurate reading.

Rotate the special tool several half-turns to ensure correct seating of the pinion bearings and position the special tool.

9. Install the special tool.
1 Position the special tool.
2 Install the differential side bearing caps.
3 Install the four differential side bearing cap bolts.

10. Note: Drive pinion bearing adjustment shims must be flat and clean.

Note: A slight drag should be felt for correct shim selection. Do not attempt to force the pinion shim between the gauge block and the gauge tube. This will minimize selection of a pinion shim thicker than required, which results in a deep tooth contact in final assembly of integral rear axle assemblies.

Use a drive pinion bearing adjustment shim as a gauge for shim selection.
- After the correct shim thickness has been determined. remove the special tools.

11. Use a press and the special tool to press the pinion bearing until it is firmly seated on the pinion and pinion shim.

12. Place a new drive pinion collapsible spacer on the pinion shaft against the pinion stem shoulder.

13. CAUTION: Installation without the correct tool can result in early seal failure. If the rear axle drive pinion seal becomes cocked during installation, remove it and install a new one.

Install a new rear axle drive pinion seal.
1 Install the outer pinion bearing.
2 Install the rear axle drive pinion shaft oil slinger in the rear axle housing.
3 Install the rear axle drive pinion seal on the special tool.

14. Note: Coat the lips of the rear axle drive pinion seal with Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-MIC75-B.

Place the special tool in the pinion seal bore and drive the rear axle drive pinion seal into place.

15. From inside the rear axle housing, install the drive pinion assembly (drive pinion, shims, inner pinion bearing, and drive pinion collapsible spacer) into the rear axle housing bore.
16. Lubricate the pinion flange splines.
- Use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A.

17. Note: Disregard the scribe marks if a new pinion flange is being installed.

Align the pinion flange with the drive pinion shaft.

18. With the drive pinion in place in the rear axle housing, install the pinion flange using the special tool.

19. Position the new pinion nut.

20. CAUTION: Under no circumstances is the pinion nut to be backed off to reduce preloads. If reduced preload is required, a new collapsible spacer and pinion nut must be installed.

CAUTION: Remove the special tool while taking preload readings with the Nm (inch-pound) torque wrench.

Using the special tool to hold the pinion flange, tighten the pinion nut.
- Rotate the pinion occasionally to make sure the cone and roller bearings are seating correctly.
- Install a Nm (inch-pound) torque wrench on the pinion nut.
- Rotating the pinion through several revolutions, take frequent cone and roller bearing torque preload readings until the original recorded preload reading is obtained.
- If the original recorded preload is lower than specifications, tighten to the appropriate specifications for used bearings. If the preload is higher than specification, tighten the nut to the original reading as recorded. Refer to Torque Specifications.
21. Install differential case in the rear axle housing.

22. Install the driveshaft.