Pinion Flange: Service and Repair

Special Tools:

Removal

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

1. Remove the rear brake discs.





2. Mark the driveshaft flange and pinion flange for correct alignment during installation.





3. Remove the four driveshaft bolts and disconnect the driveshaft.
^ Position the driveshaft out of the way.





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

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





5. Use Companion Flange Holding Tool to hold the pinion flange while removing the pinion nut.





6. Mark the driveshaft pinion flange in relation to the drive pinion stem to make sure of correct alignment during installation.





7. Use a 2-Jaw Puller for Differential Case Bearings to remove the pinion flange.

Installation
1. Lubricate the pinion flange splines.
^ Use Thermally Stable Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A.

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





2. Align the pinion flange with the drive pinion shaft.





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





4. Position the new pinion nut.

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





5. Use Companion Flange Holding Tool 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 property. 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 specification for used bearings. If the preload is higher than specification, tighten the nut to the original, trial reading as recorded.





6. Position the rear driveshaft and align the mark on the pinion flange.





7. Install the four rear driveshaft to pinion flange bolts.
8. Install the rear brake discs.