Rear differential noise

Hi,

When you reinstalled the pinion flange, how was torque determined? You had to know the preload prior to taking it apart. Then, when torquing the pinion flange nut, it gets tightened until you reach that preload that was determine prior to removal. Take a look at these directions. They explain how it's done.

Note: This is for a Ford 10.5" Differential. There is an optional Dana 80, so let me know if you have it.

2003 Ford Truck F 250 4WD Super Duty V8-6.0L DSL Turbo
Drive Pinion Flange and Drive Pinion
Vehicle Transmission and Drivetrain Differential Assembly Pinion Flange Service and Repair Procedures Ford 10.50 Inch Rear Axle Drive Pinion Flange and Drive Pinion
DRIVE PINION FLANGE AND DRIVE PINION
Drive Pinion Flange and Drive Pinion

Seal

pic 1

pic 2

Special Tool(s)

Removal

1. NOTE: The rear wheels and brake calipers must be removed to prevent brake drag during drive pinion bearing preload adjustment.

Remove the rear brake calipers.
2. Remove the driveshaft.

Pic 3

3. Install a Nm (inch-pound) torque wrench on the pinion nut, and record the rotational torque required to maintain rotation of the pinion through several revolutions.

Pic 4

4. CAUTION: After removal of the pinion nut, discard it. A new nut must be used for installation.

Use the Flange Holder to hold the pinion flange while removing the pinion nut.

Pic 5

5. Mark the pinion flange in relation to the drive pinion stem to ensure proper alignment during installation.

Pic 6

6. Use the 2-Jaw Puller to remove the pinion flange.

Pic 7

7. Force up on the metal flange of the rear axle drive pinion seal. Install gripping pliers to the seal flange and strike with a hammer until the rear axle drive pinion seal is removed.

Installation
1. Lubricate the new pinion seal.
Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.

Pic 8

2. CAUTION: If the rear axle drive pinion seal becomes misaligned during installation, remove the rear axle drive pinion seal and replace it with a new seal.

Use the Pinion Seal Replacer to install the rear axle drive pinion seal.
3. Lubricate the pinion flange splines.
Use SAE 75W-140 Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WS1-M2C192-A.

Pic 9

4. NOTE: Disregard the scribe marks if a new pinion flange is being installed.

Align the pinion flange with the drive pinion shaft.

Pic 10

5. With the pinion flange in place in the rear axle housing, install the pinion flange using the Companion Flange Replacer.

Pic 11

6. Position the new pinion nut.

Pic 12

pic 13

7. CAUTION: Under no circumstances is the pinion nut to be backed off to reduce preload. If reduced preload is required, a new collapsible spacer and pinion nut must be installed.

Use the Flange Holder to hold the pinion flange while tightening the pinion nut.
Tighten the pinion nut, rotating the pinion occasionally to make sure the cone and roller bearings are seating properly. Take frequent cone and roller bearing torque preload readings until the original recorded preload reading is obtained by rotating the pinion with a Nm (inch-pound) torque wrench.
If the original recorded preload is lower than specifications, tighten to the appropriate specification for used bearings. If the preload is higher than specification, tighten the nut to the original reading as recorded.

8. Install the driveshaft.
9. Install the brake calipers.

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I hope this helps. Let me know if you have other questions and if this is how you did it.

Take care and God Bless.

Joe

So when you let off the throttle and it is making noise that is most always the pinion making noise on the ring gear.

So when you installed the pinion nut did you reinstall the proper shim and torque the nut properly? You need to torque it to 470 lbs ft (assuming you have the Dana 80 which is the most common). Then you need to measure turning torque to make sure the preload is correct.

I attached the process below to perform this. Let me know what questions you have.