Installation

1. Clean the flange yoke seal seat surface and install rear axle drive pinion seal on Pinion Seal Replacer T79P-4676-A. Apply Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B between seal lips (if not Pregreased).

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

2. Make sure splines on the pinion shaft are free of burrs. If burrs are evident, remove them by using a fine crocus cloth. Working in a rotating motion, wipe the pinion clean.

NOTE: Check rear axle universal joint flange for burrs. Remove burrs as necessary.





3. Install rear axle drive pinion seal in to rear axle housing.
4. Apply a small amount of Premium Rear Axle Lubricant to rear axle universal joint flange splines.
5. Align mark on rear axle universal joint flange with mark on the pinion shaft. Install rear axle universal joint flange.

CAUTION: To prevent damage, the rear axle universal joint flange must never be hammered on or assembled with power tools.

6. Install a new pinion nut on pinion shaft (apply a small amount of Premium Rear Axle Lubricant on the washer side of nut).





7. Hold the rear axle universal joint flange with Companion Flange Holding Tool T78P-4851-A while tightening the nut.
8. Tighten pinion nut. Rotate differential ring gear and pinion occasionally to make sure bearing seats properly. Take frequent differential pinion bearing torque preload readings until the original recorded preload reading is obtained.
9. If the original recorded preload is less than specification, tighten until a rotational torque of 0.9-1.5 Nm (8-14 inch lbs.) preload is obtained. If the preload is higher than specification, tighten to original reading as recorded.

CAUTION: Never back off the pinion nut to reduce preload. If reduced preload is required, a new differential drive pinion collapsible spacer and pinion nut must be installed.

10. Remove Extension Housing Seal Replacer T61L-7657-A from the transmission extension housing. Install the front end of the driveshaft on the transmission output shaft.
11. Connect the rear end of the driveshaft to the rear axle universal joint flange, aligning the marks on the driveshaft and rear axle universal joint flange. Tighten rear axle universal joint flange bolts to 95-130 Nm (70-95 ft. lbs.).
12. Fill axle with Premium Rear Axle Lubricant XY-80W90-QL or -KL or equivalent meeting Ford specification WSP-M2C197-A until fluid level is within 6-14 mm (1/4-9/16 inch) below bottom of filler hole with the axle in operating position. Add 118 ml (4 oz.) of Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A to Traction-Lok rear axles. Install filler plug. Tighten to 20-40 Nm (15-29 ft. lbs.).

CAUTION: Overfilling axle can cause rear axle housing vent or seal leakage.

13. Make sure rear axle housing vent is not plugged with debris.