Lincoln Navigator: Rear Drive Axle/Differential - Vehicles With: Ford 9.75 Inch Ring Gear / Drive Pinion. Removal and Installation

Special Tool(s) / General Equipment

	205-024 (T67P-4616-A) Installer, Drive Pinion Bearing Cup
	205-090 (T75L-1165-B) Plate, Bearing/Oil Seal
	205-111 (T76P-4020-A11) Handle
	205-159 (T80T-4020-F42) Adapter for 205-S156 Pinion Depth Gauge T98T-1000-LM-1 TKIT-1998-LM (NavigatoR)
	205-160 (T80T-4020-F43) Adapter for 205-S156 Pinion Depth Gauge
	205-229 (T85T-4209-AH) Protector, Drive Pinion Thread TKIT-1985-FH-1
	205-377 (T97T-4020-A) Gauge Tube, Drive Pinion TKIT-1998-LM (NavigatoR) TKIT-1997-F/FLM/LT
	205-383 (T97T-4020-B) Depth Gauge/Aligner, Drive Pinion TKIT-1998-LM (NavigatoR) TKIT-1997-F/FLM/LT
	205-488 Installer, Drive Pinion Bearing TKIT-1999S-FLM/LT
	205-852 Inner Pinion Bearing Cup Installer TKIT-2006UP-FLM TKIT-2006UP-ROW
	205-937 Adapter, Pinion Aligning TKIT-2009C-F TKIT-2009C-ROW
	205-D064 (D84L-1123-A) Puller, Bearing
	307-003 (T57L-500-B) Holding Fixture, Transmission
	308-391 Installer, Input Shaft Bearing Cup TKIT-1999-F/FLM/LT
Rubber Mallet
Hydraulic Press
Punch
Copper Hammer

Removal

1. Remove the differential carrier.
   Refer to: Differential Carrier (205-02 Rear Drive Axle/Differential - Vehicles With: Ford 9.75 Inch Ring Gear, Removal and Installation).
   Refer to: Differential Carrier - Vehicles With: Electronic Limited-Slip Differential (205-02 Rear Drive Axle/Differential - Vehicles With: Ford 9.75 Inch Ring Gear, Removal and Installation).
   

1. Remove the drive pinion seal.
   Refer to: Drive Pinion Seal (205-02 Rear Drive Axle/Differential - Vehicles With: Ford 9.75 Inch Ring Gear, Removal and Installation).
   

1. Remove the drive pinion outer shim.
   

1. Using the special tool and a soft face mallet, tap the drive pinion outer bearing.
   Use Special Service Tool: 205-229 (T85T-4209-AH)  Protector, Drive Pinion Thread.
   Use the General Equipment: Rubber Mallet

1. Remove the drive pinion and remove and discard the drive pinion outer bearing.
   

1. Remove and discard the drive pinion collapsible spacer.
   

1. Using the special tool and a hydraulic press, remove and discard the inner drive pinion bearing.
   Use Special Service Tool: 205-D064 (D84L-1123-A)  Puller, Bearing.
   Use the General Equipment: Hydraulic Press

1. Remove the inner drive pinion bearing shim.
   

1. Using the general equipment, remove and discard the 2 drive pinion bearing cups.
   Use the General Equipment: Punch
   Use the General Equipment: Copper Hammer

Installation

1. NOTE: Make sure the drive pinion bearing cups are seated correctly or damage to the components may occur.

   Using the special tools, install the new inner and new outer drive pinion bearing cups.
   Use Special Service Tool: 205-024 (T67P-4616-A)  Installer, Drive Pinion Bearing Cup. , 205-852  Inner Pinion Bearing Cup Installer. , 308-391  Installer, Input Shaft Bearing Cup.

1. NOTICE: Use the same drive pinion bearings and the drive pinion bearing adjustment shim from the drive pinion bearing adjustment shim selection procedure for final assembly or damage to the component may occur.

   NOTE: Install new drive pinion bearings without any additional lubricant since the anti-rust oil provides adequate lubricant without upsetting the drive pinion bearing preload settings.

   Assemble the special tools and new bearings in the differential housing.
   Use Special Service Tool: 205-159 (T80T-4020-F42)  Adapter for 205-S156 Pinion Depth Gauge. , 205-160 (T80T-4020-F43)  Adapter for 205-S156 Pinion Depth Gauge. , 205-383 (T97T-4020-B)  Depth Gauge/Aligner, Drive Pinion. , 205-937  Adapter, Pinion Aligning.

1. • NOTE: This step duplicates final drive pinion bearing preload.

     Tighten the special tool to the specified torque.
     Use Special Service Tool: 205-111 (T76P-4020-A11)  Handle.
     Torque: 18 lb.in (2 Nm)
   • Slowly rotate and record the rotational torque readings.
     

1. NOTE: Position the Adapter so it does not contact the housing.

   NOTE: Offset the Adapter to obtain an accurate reading.

   Rotate the adapter several half turns to seat the drive pinion bearings and position the adapter.
   

1. • Position the special tool.
     Use Special Service Tool: 205-377 (T97T-4020-A)  Gauge Tube, Drive Pinion. , 205-159 (T80T-4020-F42)  Adapter for 205-S156 Pinion Depth Gauge. , 307-003 (T57L-500-B)  Holding Fixture, Transmission.
   • Install the differential bearing caps and differential bearing cap bolts.
     Torque: 83 lb.ft (112 Nm)

1. NOTE: Drive pinion bearing adjustment shims must be flat and clean.

   NOTE: A slight drag should be felt for correct drive pinion bearing adjustment shim selection. Do not attempt to force the drive pinion bearing adjustment shim between the gauge block and the gauge tube. This will minimize selection of a drive pinion bearing adjustment shim thicker than required, which results in a deep tooth contact in the final assembly of integral axle assemblies.

   Use a drive pinion bearing adjustment shim as a gauge for drive pinion bearing adjustment shim selection.
   Use Special Service Tool: 205-377 (T97T-4020-A)  Gauge Tube, Drive Pinion. , 205-159 (T80T-4020-F42)  Adapter for 205-S156 Pinion Depth Gauge. , 307-003 (T57L-500-B)  Holding Fixture, Transmission.

1. • NOTE: The differential bearing caps need to stay in the correct orientation for installation.

     Remove the differential bearing cap bolts and differential bearing caps, remove the special tools.
     Use Special Service Tool: 205-377 (T97T-4020-A)  Gauge Tube, Drive Pinion.

1. Remove the special tool.
   Use Special Service Tool: 205-111 (T76P-4020-A11)  Handle.

1. Remove the special tools.
   Use Special Service Tool: 205-159 (T80T-4020-F42)  Adapter for 205-S156 Pinion Depth Gauge. , 205-383 (T97T-4020-B)  Depth Gauge/Aligner, Drive Pinion. , 205-937  Adapter, Pinion Aligning. , 205-160 (T80T-4020-F43)  Adapter for 205-S156 Pinion Depth Gauge.

1. NOTE: The differential bearing caps need to stay in the correct orientation for installation.

   Install the drive pinion inner bearing and selected drive pinion bearing adjustment shim until they are firmly seated on the drive pinion.
   Use Special Service Tool: 205-090 (T75L-1165-B)  Plate, Bearing/Oil Seal. , 205-488  Installer, Drive Pinion Bearing.
   Use the General Equipment: Hydraulic Press

1. Remove the special tools.
   Use Special Service Tool: 205-090 (T75L-1165-B)  Plate, Bearing/Oil Seal. , 205-488  Installer, Drive Pinion Bearing.

1. Install the new drive pinion collapsible spacer.
   

1. Install the new outer differential pinion bearing, differential outer differential pinion shim and the differential pinion.
   

1. NOTE: When installing the drive pinion flange and pinion nut with no differential carrier installed, the drag torque (torque to turn) should be 2 to 3 Nm (16-29 in-lbs).

   Install the drive pinion seal.
   Refer to: Drive Pinion Seal (205-02 Rear Drive Axle/Differential - Vehicles With: Ford 9.75 Inch Ring Gear, Removal and Installation).
   

1. Install the differential carrier.
   Refer to: Differential Carrier (205-02 Rear Drive Axle/Differential - Vehicles With: Ford 9.75 Inch Ring Gear, Removal and Installation).
   Refer to: Differential Carrier - Vehicles With: Electronic Limited-Slip Differential (205-02 Rear Drive Axle/Differential - Vehicles With: Ford 9.75 Inch Ring Gear, Removal and Installation).