Pinion Gear: Service and Repair

Special Tools:

Removal
1. Remove the differential case.

2. CAUTION: Record the torque necessary to maintain rotation of the drive pinion gear through several revolutions prior to removing the pinion flange.

Remove the pinion flange.
3. Remove the rear axle drive pinion seal.

4. Remove the rear axle drive pinion shaft oil slinger.

5. Using the special tool and a soft-faced hammer, drive the pinion assembly out of the outer differential pinion bearing, and remove the drive pinion through the rear of the housing.
6. Remove the outer differential pinion bearing.

7. Remove and discard the collapsible spacer.

8. Using the special tool and a suitable press, remove the inner differential pinion bearing.

9. Note: Do not remove the pinion bearing cups from the axle housing unless the cups are damaged.

To remove the bearing cups, tap alternately (with a brass drift of suitable length) on opposite sides of the cup to prevent the cup from cocking in the casting.

Installation
Using 205-054

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 in their bores.
Using 205-153 and 205-D055

3. Using the special tools, drive the outer pinion bearing cup into the axle housing.

4. Using the special tools, drive the inner pinion bearing cup into the axle housing.
Setting pinion depth

5. CAUTION: Always install new pinion bearings when installing new 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.

Check that the cups have seated correctly in their bores.

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

Assemble and position the special tools in the axle housing.
1. Position the Screw.
2. Position the Aligning Adapter.
3. Position the inner pinion bearing.
4. Position the Gauge Disc.
5. Position the Gauge Block.
6. Position the outer pinion bearing.
7. Thread on the Handle.

7. Note: This step simulates pinion bearing preload.

Using a Nm (inch/pound) torque wrench, tighten the Driver Handle to the specification.

8. Note: Offset the Gauge Block to obtain an accurate reading.

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

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

10. Note:
^ Use only flat, clean drive pinion bearing adjustment shims.
^ Selection of too thick a pinion shim results in a deep tooth contact at final assembly of integral rear axle assemblies. Do not attempt to force the pinion shim between the Gauge Block and the Gauge Tube. A slight drag indicates correct shim selection.

Use a drive pinion bearing adjustment shim as a gauge for shim selection.
^ Check the drive pinion bearing adjustment shim thickness between the Gauge Block and the Gauge Tube.
^ After determining the proper shim thickness, remove the special tools.

11. Using the special tool and a suitable press, seat the pinion bearing firmly against the drive pinion gear.

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

13. Install the outer pinion bearing.

14. Install the rear axle drive pinion shaft oil slinger.

15. 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-M1C75-B.

Place the rear axle drive pinion seal on the special tool.

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

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

19. Note: Disregard the alignment marks if installing a new pinion flange.

Align the pinion flange with the drive pinion shaft.

20. Using the special tools, install the pinion flange.

21. CAUTION:
^ Do not under any circumstance loosen the pinion nut to reduce preload. If it is necessary to reduce preload, install a new collapsible spacer and pinion nut.
^ Remove the special tool while taking preload readings with the Nm (inch-pound) torque wrench.

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 seat correctly. Take frequently differential pinion bearing torque preload readings by rotating the pinion with a Nm (inch-pound) torque wrench.
^ If the preload recorded prior to disassembly is lower than the specification for used bearings, then tighten the pinion nut to specification. If the preload recorded prior to disassembly is higher than the specification for used bearings, then tighten the pinion nut to the original reading as recorded.
^ Refer to the torque specification for new pinion bearings
22. Install the differential case and the remaining components.