Pinion Gear: Service and Repair

Special Tools:

Removal
1. Remove the differential case.

2. CAUTION: Record the torque necessary to maintain rotation of the pinion through several revolutions prior to removing the pinion flange (48S1).

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 pinion bearing, and remove the pinion through the rear of the housing.
6. Remove the outer pinion bearing.

7. Remove and discard the collapsible spacer.

8. Using the special tool and a suitable press, remove the inner 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 205-024

1. Position the special tools and the inner and outer bearing cups in their respective axle housing 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 scat the pinion bearing cups in their bores.

Using 205-153 and 205-DOS5

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 and pinion bearings 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 Handle to the specification.

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

Rotate the Gauge Block several half-lures to make sure of 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.

Note: 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 pinion bearing adjustment shim thickness between the Gauge Block and the Gauge Tube.
- After determining the correct shim thickness, remove the special tools.

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

12. Place a new 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. CAUTION: Installation without the correct tool can result in early seal failure.

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. CAUTION: If the rear axle drive pinion seal becomes cocked during installation, remove it and install a new one.

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

17. Install the pinion assembly (pinion, shims, inner pinion bearing, and collapsible spacer) into the rear axle housing bore.
18. Lubricate the pinion flange splines.
- Vehicles with 4.0L SOHC and 4.0L EI with a conventional differential, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A.
- Vehicles with 4.0L SOHC and 4.0L EI with Limited Slip differential and 5.0L, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-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.

CAUTION: Remove the special tool when 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 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 the torque specification for new pinion bearings.
22. Install differential case and the remaining components.