hey everyone... i have a 2000 f150 with 3:55 rearend gears. around 8-9 months ago i had all the rearend bearings replaced due to a whine in the rearend. the pinion bearing had a slight grove in it. in the last few days the dredded noise is back at speeds between 80-100 km's hr. i'm pretty sure its the same problem, but i am only gonna replace the pinion bearings this time myself, had a garage do it last time. i know that i will need a pinion seal, inner and outter bearing and a crush sleeve. My question is, is it much trouble to crush the sleeve using a breaker bar or socket/ratchet? i dont have a big compressor and impact gun like the garage. how do i know when its crushed? is there torque specs? do u just crank it so tight as u can? i hear ppl saying things like back lash. what does this mean? at the dealer they say it will cost me about $1200..

Thanks

 

anyone??

 

When i did mine I was manageable, i bought a kit from summitracing. You are shooting for a prevailing torque of about 14 in lbs if i remember right. You might need to custom fabricate a tool to hold the pinion as your torque the nut though.

 

OVERHAUL
NOTE: If vehicle is equipped with Traction-Lok, see appropriate TRACTIONLOK
article.
DISASSEMBLY
Raise and support vehicle. Drain lubricant and remove housing cover. Mount dial indicator and
measure and record ring gear runout. See RING GEAR RUNOUT under INSPECTION
PROCEDURES. Measure and record ring gear backlash. See Fig. 3 . See DIFFERENTIAL
BEARING PRELOAD & RING GEAR BACKLASH under REASSEMBLY &
ADJUSTMENTS.
1.
Remove axle shafts. See AXLE SHAFT & BEARING under REMOVAL &
INSTALLATION. Place alignment marks on drive shaft, yoke and pinion flange for reassembly
reference.
2.
Scribe alignment marks on pinion flange and drive shaft yoke for installation reference.
Remove 4 drive shaft bolts and wire drive shaft aside. Mark differential bearing caps for
reassembly reference and note arrow position. Loosen bearing cap bolts. Pry out differential
case, bearing races and shims until loose in bearing caps.
3.
NOTE: Bearing races and caps must be installed in original positions.
Remove bearing caps and differential. Remove pinion nut and pinion flange. Drive pinion out
of front bearing using soft-faced hammer. Remove pinion from housing. Remove oil seal using
slide hammer.
4.
NOTE: DO NOT remove pinion bearing races unless damaged. If races
are replaced, bearings must also be replaced.
Remove front bearing. Mount bearing puller on pinion shaft, and press shaft out of bearing.
Remove, measure, and record thickness of shim located behind bearing. Remove differential
side bearings with a puller.
5.
NOTE: Tab on exciter ring must be aligned with slot in differential case.
Mark differential case and ring gear for reassembly reference. Remove and discard ring gear
mounting bolts. Press or tap off ring gear. Remove exciter ring from differential case (if
necessary). If exciter ring is removed from differential case, a NEW exciter ring must be
installed. Remove pinion shaft lock bolt and remove shaft. Remove pinion gears, side gears and
thrust washers.
6.
Fig. 3: Measuring Ring Gear Backlash
Courtesy of FORD MOTOR CO.
CLEANING & INSPECTION
DRIVE AXLE - 8.8" & 10.25" RING GEAR DIFFERENTIALS -1997 Ford Pickup F150 Page 1 of 5
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Clean all parts thoroughly in solvent. Check pinion and ring gear teeth for scoring, excessive wear,
nicks and chipping. Check bearing races for deep scores or galling. Check carrier bearings for wear or
damage. Replace components as necessary.
Anti-Lock Brake Sensor
Check sensor pole piece for loose metal particles. Clean if necessary.
Exciter Ring
Ensure exciter ring is properly pressed onto differential case. Examine ring for chips or missing teeth.
Bearing Races
Check bearing races for scoring or galling. If a .0015" (.038 mm) feeler gauge can be inserted
between a race and bottom of its bore at any point, race must be reseated.
Bearing & Roller Assemblies
When rotated in races, bearing rollers must turn without roughness. Check roller ends for step wear. If
damaged, both parts should be replaced.
Pinion Flange
Ensure flange half-rounds and lugs have not been damaged. End of flange contacting bearing,
counterbore and seal surface must be smooth and free of damage.
Gears
Examine pinion and ring gear teeth for scoring, excessive wear, and excessive chipping. Worn or
damaged gears CANNOT be rebuilt to correct noisy condition.
Axle Housing
Ensure differential and pinion bearing bores are smooth. Remove any nicks or burrs from mounting
surfaces.
Differential Case
Ensure hubs where bearings mount are smooth. Check differential case bearing shoulders for damage.
Bearing assemblies will fail if they DO NOT seat firmly against shoulders. Ensure differential side
gears rotate freely in counterbores.
REASSEMBLY & ADJUSTMENTS
NOTE: Ring and pinion gears must be replaced in matched sets.
DRIVE AXLE - 8.8" & 10.25" RING GEAR DIFFERENTIALS -1997 Ford Pickup F150 Page 2 of 5
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Differential Case
Lubricate all parts with axle lubricant. Place side gears and thrust washers into case. Place
pinion gears and thrust washers opposite each other in case openings, and in mesh with side
gears.
1.
Install ring gear with NEW mounting bolts. If bolts are covered with Green coating over 1/2" of
threaded area, install and tighten bolts. If NEW bolts do not have Green coating, apply small
amount of Loctite to bolt threads then tighten bolts.
2.
If bearing races have been replaced, NEW bearing and roller assemblies should be installed.
Races must be seated in bores so a .0015" (.038 mm) feeler gauge will not fit between race and
bottom of bore.
3.
Pinion Depth
Assemble Axle Pinion Depth Gauge Set (T79P-4020-A) and install aligning adapter, gauge
disc, gauge block screw and gauge block.
1.
Place rear pinion bearing over aligning disc and into bearing race of axle housing. Install front
pinion bearing into front bearing race. Place tool handle onto screw and finger tighten. See Fig.
4 .
2.
Ensure pinion depth measuring tools are properly installed and tightened. Apply a light film of
oil to pinion bearings. Rotate gauge block several times to seat bearings.
3.
Tighten tool handle to 20 ft. lbs. (27 N.m). Final position of gauge block should be 45 degrees
above axle shaft centerline. Clean differential bearing bores thoroughly and install gauge tube.
Install bearing caps and bolts. Tighten bearing cap bolts to specification. See TORQUE
SPECIFICATIONS .
4.
Using flat pinion shims as a gauge for shim selection, hold gauge block in proper position and
measure clearance between gauge block and tube. Correct shim selection is accomplished when
a slight drag is felt as shim is drawn between gauge block and tube.
5.
Fig. 4: Installing Pinion Depth Measuring Tools (Tools are included in Axle Pinion Depth
Gauge Set)
Courtesy of FORD MOTOR CO.
Pinion Bearing Preload
Place pre-selected shim on pinion shaft. Press bearing onto shaft until bearing and shim are
firmly seated against shoulder of shaft. Install NEW collapsible spacer on pinion shaft
1.
Lubricate bearings with axle lubricant. Install front pinion bearing in housing. Install NEW
pinion oil seal. Insert pinion flange into oil seal and hold firmly in place.
2.
NOTE: If installing a NEW pinion flange, disregard scribed mark on pinion
shaft.
From rear of axle housing, insert pinion shaft into flange. Install a NEW pinion nut on pinion
shaft and gradually tighten pinion nut while holding flange.
3.
DRIVE AXLE - 8.8" & 10.25" RING GEAR DIFFERENTIALS -1997 Ford Pickup F150 Page 3 of 5
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Check bearing preload often. As soon as preload is measured, turn pinion shaft in both
directions several times to seat bearings. Hold pinion flange with Pinion Flange Holder (T78P-
4851-A) while tightening nut.
4.
Tighten pinion nut and continue to measure pinion bearing preload until the specified pinion
torque is obtained. See DIFFERENTIAL SPECIFICATIONS . If bearing preload is exceeded
before torque specification is reached, replace collapsible spacer. Install NEW pinion nut and
repeat procedures. DO NOT loosen pinion nut to reduce pinion bearing preload.
5.
Differential Bearing Preload & Ring Gear Backlash
With pinion depth set and pinion installed, place differential case and gear assembly (with
bearings and races) into axle housing.
1.
Install a .265" (6.73 mm) shim on left (ring gear side) side of differential. Install left bearing
cap and bolts. Finger tighten bolts. Select and install largest shim that will fit, with a slight drag,
on pinion gear side (right side) of differential. Install right bearing cap and bolts and tighten all
cap bolts to specification. See TORQUE SPECIFICATIONS .
2.
Rotate gear assembly to ensure free operation. Check ring and pinion backlash. See Fig. 3 . If
backlash is .008-.015" (.20-.38 mm), proceed to step 6 . If backlash is zero, add .020" (.51 mm)
to shim size on right side, and subtract .020" (.51 mm) from shim size on left side.
3.
If backlash is less than .008" (.20 mm) or more than .015" (.38 mm), increase or decrease shim
size where necessary to correct reading. See Fig. 5 . See BACKLASH-TO-SHIM
THICKNESS CONVERSION table.
4.
Retighten bearing cap bolts and rotate gear assembly several times. Recheck backlash and
correct if necessary. Increase both left and right shim sizes .006" (.15 mm), and reinstall for
correct preload.
5.
Ensure shims are seated and gear assembly turns freely. Using marking compound, check gear
tooth contact pattern. See GEAR TOOTH CONTACT PATTERNS article in GENERAL
INFORMATION.
6.
BACKLASH-TO-SHIM THICKNESS CONVERSION
Required Change In Backlash In. (mm) Change In Shim Thickness In. (mm)
.001 (.03) .002 (.05)
.002 (.05) .002 (.05)
.003 (.08) .004 (.10)
.004 (.10) .006 (.15)
.005 (.13) .006 (.15)
.006 (.15) .008 (.20)
.007 (.18) .010 (.25)
.008 (.20) .010 (.25)
.009 (.23) .012 (.30)
.010 (.25) .014 (.35)
.011 (.28) .014 (.35)
.012 (.30) .016 (.41)
.013 (.33) .018 (.46)
.014 (.35) .018 (.46)
DRIVE AXLE - 8.8" & 10.25" RING GEAR DIFFERENTIALS -1997 Ford Pickup F150 Page 4 of 5
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Required Change In Backlash In. (mm) Change In Shim Thickness In. (mm)
.015 (.38) .020 (.51)
Fig. 5: Adjusting Backlash
Courtesy of FORD MOTOR CO.
Final Assembly
Clean differential housing surface and apply a continuous bead of silicone sealant to housing cover.
Install cover and tighten bolts to specification. See TORQUE SPECIFICATIONS . Install drive
shaft. To complete assembly, reverse disassembly procedure. Fill differential until fluid level is about
1/4" below bottom of filler plug hole. Adjust brakes if required.

 

thanks...... now all i need is to try and figure out what to use to hold the pinion in place... thanks again

 

just make a C that bolts into 2 of the pinion holes and weld a bar into that.

 

That's a great detailed description of diff. o/haul. I use an old snap-on torquometer to set pinion preload. Basically it's just a torquewrench witha guage rather than a click. This way I can rotate the pinion several revolutions qhile watching the torque required to do so.

 

How did the overhaul come along?? Is your noise gone? And if it is a "whine" type noise, I would look into getting a new ring and pinion