Drive Pinion

Drive Pinion

Special Tools:

Special Tool(s)

Disassembly





1. Remove the hex nut.





2. CAUTION: Hammering on the pinion flange will close in the bearing bores and misalign the flange lugs. This will result in premature failure of the journal needle bearings/other driveline components. Serious damage will also occur internally to the differential ring gear and pinion set/pinion bearings by hammering on external parts.

Using the special tool, remove the pinion flange.





3. Remove the pinion seal.





4. CAUTION: Position a block of wood under the pinion to avoid damage to the gear teeth.

NOTE: The outer bearing is press fit.

Press the pinion through the outer pinion bearing, and remove the pinion.





5. Remove the pinion preload spacer.
- Measure and record the spacer thickness. Set the spacer aside for use in assembly.





6. If reusing the gear set, remove the inner pinion bearing with a suitable puller.





7. If discarding the pinion bearings, remove the outer and inner pinion bearing cups.

8. CAUTION: Alkaline cleaning solutions will damage machine surfaces. Use only emulsion cleaners or petroleum based cleaning solvent.

CAUTION: Use soft, clean, listless towels to dry the components.

CAUTION: Never spin-dry bearings with compressed air. This will damage the mating surfaces due to a lack of lubrication.

CAUTION: After drying, lightly coat the parts with rust inhibitor or clean lubricant to prevent damage from corrosion. Wrap all parts that are going to be in storage for a prolonged period in wax paper.

Clean and dry the components as necessary.





9. Inspect the pinion flange for grooves in the sealing surface caused by contamination.
- If grooves are detectable with a fingernail, repair the flange with a CR approved sleeve or install a new flange.

Assembly

Initial Assembly





1. Press the inner pinion bearing onto the pinion.





2. Press the inner and outer pinion bearing cups into the carrier until seated.
- Use a 0.0381 mm (0.0015 inch) feeler gauge to verify the bearing cups have completely seated in the bearing bores.
- Lubricate the bearing cups and cone.





3. Seat the outer pinion bearing on the pinion.
1 Seat the inner pinion bearing into the cup by positioning a 152.4 x 152.4 x 152.4 mm (6 x 6 x 6 inch) block of-wood under the pinion.
2 Place the original pinion preload spacer onto the pinion.
3 Place the outer pinion bearing onto the pinion.
4 Using a suitable press, seat the outer bearing on the pinion.





4. NOTE: Do not install the pinion seal at this time.

Using the special tool, install the pinion flange.





5. Install the hex nut.
- Using a suitable torque multiplier, tighten the hex nut.





Measuring pinion bearing preload torque
6. Measure the torque to rotate.
- Take torque measurements every fourth revolution.
- Proceed to Pinion bearing preload adjustment in this procedure if the bearing preload torque is not within the specifications. Proceed to Final assembly in this procedure if the bearing preload torque is within the specifications.








Pinion bearing preload adjustment

7. NOTE: Also refer to the following illustration.

Adjust the pinion bearing preload by installing a new pinion bearing preload spacer.
- To increase the preload, install a thinner spacer. To decrease the preload, install a thicker spacer.
- The pinion bearing preload spacers are available in sizes from 7.26 to 8.00 mm (0.286 to 0.315 inch).
- Always measure the new spacer before installing it.
- On a flat surface, sand the next thicker size spacer with emery cloth to the required thickness to obtain a closer adjustment. Thoroughly wash the spacer to remove the emery cuttings before installation.
- A 0.0254 mm (0.001 inch) change in the spacer thickness will change the torque rate approximately 3.3894 Nm (30 inch lbs.).
- Repeat Measuring pinion bearing preload torque and Pinion bearing preload adjustment in this procedure until the rotational torque is within specifications.





Final assembly
8. Using a suitable torque multiplier, remove the hex nut.





9. CAUTION: Hammering on the pinion Range will close in the bearing bores and misalign the flange lugs. This will result in premature failure of the journal needle bearings/other driveline components. Serious damage will also occur internally to the differential ring gear and pinion set/pinion bearings by hammering on external parts.

Using the special tool, remove the pinion flange.





10. Using the special tool, install the pinion seal.
- A rotational torque of 1.6947 - 5.0841 Nm (15 - 45 inch lbs.) is acceptable with the pinion seal installed.





11. Using the special tool, install the pinion flange.





12. Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to the pinion threads, and install a new hex nut.
- Using a suitable torque multiplier, tighten the nut.
13. Assemble the carrier.