Rear Differential

Drive Pinion Flange and Drive Pinion Seal





Special Tool(s)





Material





Removal
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the rear wheel and tire assemblies.





3. CAUTION: Remove the rear brake calipers to prevent drag during the pinion bearing preload adjustment.

CAUTION: Do not remove the guide pins or guide pin boots unless a problem is suspected. The guide pins are meant to be sealed for life and are not repairable. Use silicone brake caliper grease or equivalent for re-lubing the caliper slide pins. Other greases can swell the guide pin boots, resulting in contamination and accelerated corrosion and wear of the caliper slide pin mechanism.

CAUTION: Do not allow the calipers to hang from the brake hoses.

Remove the rear disc brake caliper assembly.
1 Remove the disc brake caliper bolts.
2 Lift the rear disc brake caliper off the knuckle.
^ Support the caliper assembly with a length of mechanic's wire.





4. Index mark the driveshaft flange and pinion flange for correct alignment during installation.

5. NOTE: If new driveshaft flange bolts are not available, coat the threads of the original driveshaft flange bolts with threadlock and sealer.

Remove the driveshaft flange bolts.





6. CAUTION: The driveshaft flange fits tightly on the pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft flange from the pinion flange. Pry only in the area shown, with a suitable tool, to disconnect the driveshaft flange from the pinion flange.

Using a suitable tool as shown, disconnect the driveshaft flange from the pinion flange, then using mechanic's wire, position the driveshaft aside.





7. Install a Nm (inch lbs.) torque wrench on the pinion nut and record the torque necessary to maintain rotation of the drive pinion gear through several revolutions.





8. Use the special tool to hold the pinion flange, to remove and discard the pinion nut.





9. Index mark the pinion flange and drive pinion gear to maintain initial balance during installation.





10. Using the special tool, remove the pinion flange.





11. If necessary, use a screwdriver to force up the metal flange of the pinion seal. Install gripping pliers and strike with a hammer to remove the drive pinion seal.

Installation
1. If removed, lubricate the lips of the new drive pinion seal.
^ Use long-life grease.





2. CAUTION: If the drive pinion seal becomes misaligned during installation, remove the drive pinion seal and install a new drive pinion seal.

NOTE: Always install a new drive pinion seal when removed.

If the drive pinion seal was removed, use the special tool to install a new drive pinion seal.
3. Inspect the pinion flange seal journal for rust, nicks and scratches prior to installing the pinion flange. Polish the seal journal with fine crocus cloth, if necessary.
4. Lubricate the pinion flange splines.
^ Use long-life grease.





5. NOTE: Disregard the index marks if installing a new pinion flange.

Position the pinion flange.





6. Using the special tools, install the pinion flange.





7. CAUTION: Do not under any circumstance loosen the pinion nut to reduce drive pinion bearing preload. If it is necessary to reduce drive pinion bearing preload, install a new differential drive pinion collapsible spacer and pinion nut.

Tighten the pinion nut to set the drive pinion bearing preload.
^ Rotate the drive pinion gear occasionally to make sure the drive pinion bearings seat correctly. Take frequent drive pinion bearing preload readings by rotating the drive pinion gear with a Nm (inch lbs.) torque wrench.
^ Refer to the torque specification for used pinion bearings in the Specifications.





8. CAUTION: To prevent interference with the rear disc brake caliper operation, install only the correct disc brake caliper bolt.

NOTE: Make sure the stainless steel shoe slippers are correctly positioned. Install new slippers if worn or damaged.

NOTE: Use the disc brake pad spreader to spread pads for reassembly.

Install the brake disc caliper, then install the disc brake caliper bolts.
^ Tighten to 32 Nm (24 ft. lbs.).





9. CAUTION: The driveshaft centering socket yoke fits tightly on the pinion flange pilot. To make sure that the yoke seats squarely on the pinion flange, tighten the driveshaft flange bolts evenly in a cross-pattern as shown.

CAUTION: If new driveshaft flange bolts are not available, coat the threads of the original driveshaft flange bolts with theadlock and sealer.

Install the driveshaft, then the driveshaft flange bolts.
^ Tighten to 112 Nm (83 ft. lbs.).
10. Install the rear wheel and tire assemblies.