Pinion Flange: Service and Repair

Drive Pinion Flange and Drive Pinion Seal








Special Tool(s)

Removal

1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air sprags, which can result in shifting of the vehicle during these operations.

Remove the rear wheel and tire assemblies.

2. CAUTION: Remove the rear brake discs to prevent brake drag during drive pinion bearing preload adjustment.

Remove the rear brake discs.





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





4. Remove the four bolts.

5. CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the yoke from the flange. Pry only in the area shown with a suitable tool to disconnect the yoke from the flange.





Using a suitable tool as shown, disconnect the driveshaft centering socket yoke from the rear axle pinion flange.
- Position the driveshaft aside.





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

7. CAUTION: Discard the nut after removing it. Install a new nut during installation.





Use the special tool to hold the pinion flange while removing the nut.





8. Index-mark the pinion flange and the drive pinion stem for correct alignment during installation.





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





10. Using a screwdriver, force the rear axle drive pinion seal metal flange up and strike it with a hammer.





11. Using gripping pliers and a hammer, remove the seal.

Installation
1. Coat the new rear axle drive pinion seal lips with lubricant.
- Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specifications ESA-MlC75-B.

2. CAUTION: Installation without the correct tool can result in early seal failure.

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





Using the special tool, install the rear axle drive pinion seal.
3. Lubricate the pinion flange splices.
- Use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A.

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





Position the pinion flange.





5. Using the special tool, install the pinion flange.





6. Position the new nut.

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

CAUTION: Remove the special tool while taking preload readily with the Nm (inch-pound) torque wrench.





Use the special tool to hold the pinion flange while tightening the nut.
- Rotate the pinion occasionally to make sure the differential pinion bearings seat correctly. Take frequent differential pinion bearing preload readings by rotating the pinion with a Nm (inch-pound) torque wrench.
- If the preload recorded prior to disassembly is lower than the specification for used bearings, tighten the nut to specification. If the preload recorded prior to disassembly is higher than the specification for used bearings, tighten the nut to the original reading as recorded.
- Refer to torque specifications for used pinion bearings.





8. Align the index marks.

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





Install the driveshaft.
10. Install the rear brake discs and calipers.

11. NOTE: If equipped with air suspension, reactivate the system.

Install the rear wheel and tire assemblies.