Installation

NOTE: Check rear axle universal joint flange for burrs. Remove burrs as necessary. Make sure surfaces of rear axle universal joint flange have not been damaged in removing driveshaft or in removing rear axle universal joint flange from pinion. The end of the rear axle universal joint flange that contacts the bearing cone as well as the nut counterbore and seal surface must be smooth and free of nicks.

1. Make sure splines on drive pinion stem are free of burrs. If burrs are evident, remove them using a fine crocus cloth. Working in a rotating motion wipe pinion clean. Clean flange yoke seal seat surface and install rear axle drive pinion seal on Pinion Seal Replacer T79P-4676-A.





2. Install rear axle drive pinion seal in rear axle housing.

CAUTION: Installation without proper tool may result in early flange yoke seal failure. If rear axle drive pinion seal becomes cocked during installation, remove and replace with new rear axle drive pinion seal.

3. Apply a small amount of SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or -KL meeting Ford specification WSP-M2C 197-A or equivalent to rear axle universal joint flange splines.

NOTE: Check rear axle universal joint flange for burrs. Remove burrs as necessary. Be sure surfaces of flange have not been damaged in removing driveshaft or in removing flange from pinion. The end of rear axle universal joint flange that contacts bearing cone as well as nut counterbore and seal surface must be smooth and free of nicks.

4. Align mark on rear axle universal joint flange with mark on pinion stem. Install rear axle universal joint flange.

CAUTION: The rear axle universal joint flange must never be hammered on or assembled with power tools.

Install new pinion nut on pinion stem. Apply a small amount of SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or -KL or equivalent meeting Ford specification WSP-M2C197-A on washer side of nut.





5. Hold rear axle universal joint flange with Companion Flange Holding Tool T78P-4851-A while tightening pinion nut. Rotate pinion occasionally to make sure of proper differential pinion bearing seating.





6. Take frequent pinion bearing torque preload readings until original preload reading is obtained.
7. If original recorded preload is less than specification tighten used differential pinion bearing to 0.9-1.6 Nm (8-14 in. lbs.) and new differential pinion bearing to 1.8-3.2 Nm (16-28 in. lbs.). If preload is higher than specification tighten to original reading as recorded.
8. Never back off pinion nut to reduce preload. If reduced preload is required, a new differential drive pinion collapsible spacer and pinion nut must be installed.





9. Using a jackstand, raise and locate rear axle housing on rear axle differential front lower insulator bolts.





10. Install rear axle differential front lower insulator nuts. Tighten to 92-136 Nm (68-100 ft. lbs.).





11. Remove rear axle differential rear insulator bolt from pivot position.





12. Install rear axle differential rear insulator bolts in axle housing cover mount. Tighten to 108-136 Nm (80-100 ft. lbs.).





13. Align marks on driveshaft and rear axle universal joint flange. Install retaining bolts. Tighten to 95-130 Nm (70-95 ft. lbs.).
14. Fill rear axle housing with Premium Rear Axle Lubricant XY-80W90-QL or -KL meeting Ford specification WSP-M2C 197-A or equivalent to 6 mm (1/4 inch) below the filler hole. For complete refill of Traction-Lok(r) axles, add 4 ounces of Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A.





15. Install filler plug. Tighten to 28-40 Nm (21-29 ft. lbs.).
16. Lower vehicle.