Item 17: Pinion Position Shim and Item 16: Inner Pinion Bearing Assembly Note

WARNING: This page is about a different car, the 2003 Mercury Mountaineer and 2003 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Apply a light film of oil to the differential pinion bearings before installing them.

Fig 1: Installing Components In Differential Housing According To Position Sequence

Courtesy of FORD MOTOR CO.

Assemble and position the following in the differential housing.
1. Position the Screw.
2. Position the Aligning Adapter.
3. Position the inner differential pinion bearing.
4. Position the Gauge Disc.
5. Position the Gauge Block.
6. Position the outer differential pinion bearing.
7. Thread on the Handle.
Using a Nm (inch-pound) torque wrench, tighten the Handle.

Fig 2: Tightening Handle Using Torque Wrench
Courtesy of FORD MOTOR CO.

NOTE: Offset the Gauge Block to obtain an accurate reading.

Fig 3: Checking Differential Pinion Bearings Seat Correctly Using Special Tool

Courtesy of FORD MOTOR CO.

Rotate the Gauge Block several half turns to make sure the differential pinion bearings seat correctly. Position the special tool as shown.
Install the special tool and the paper shipping tags.
1. Position the special tool and the paper shipping tags.
2. Install the differential bearing caps.
3. Install the bolts.
Fig 4: Installing Special Tool And Paper Shipping Tags
Courtesy of FORD MOTOR CO.

NOTE: Use a feeler gauge, or flat, clean drive pinion position shims as a measuring device.

NOTE: Selection of a shim that is too thick results in deep tooth contact at final assembly.

Fig 5: Checking Shim Thickness

Courtesy of FORD MOTOR CO.

Do not attempt to force the gauge or shim between the Gauge Block and the Gauge Tube. A slight drag indicates a correct selection.
Using a feeler gauge, or a flat, clean drive pinion position shim, measure between the Gauge Block and the Gauge Tube. Record the measurement.
- Remove the special tools after determining the correct shim thickness.
Select the correct thickness drive pinion position shim.
- New drive pinion position shims are available in the following sizes:
  
  Fig 6: Shim Thickness Sizes Table (1 Of 2)
  Courtesy of FORD MOTOR CO.
  
  Fig 7: Shim Thickness Sizes Table (2 Of 2)
  Courtesy of FORD MOTOR CO.
- If installing a new gearset, notice the plus (+), minus (-), or zero (0) etching on both the original and the new drive pinion, and adjust the thickness of the new shim according to the following charts. If etching is plus (+), subtract the number from the gauged shim thickness. If etching is minus (-), add the number to the gauged shim thickness.
Fig 8: Rotating Pinion On Ring Gear
Courtesy of FORD MOTOR CO.
Install the pinion position shim and the differential pinion bearing.
- Using the special tool and a suitable press, seat the differential pinion bearing firmly against the pinion position shim.
Fig 9: Installing Pinion Position Shim And Differential Pinion Bearing
Courtesy of FORD MOTOR CO.