Drive Pinion Flange and Drive Pinion Seal

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 LH side of the luggage compartment. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations.

Turn the air suspension switch off.
2. Position the vehicle on a hoist.
3. Remove the rear tires and wheels.





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

NOTE: When removing the rear brake caliper in this procedure, it is not necessary to disconnect the hydraulic lines.

Remove the rear brake discs.
^ Support the rear brake caliper with mechanics wire.





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





6. Remove the four bolts.





7. 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.





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





9. 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.





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





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





12. Using the special tools, remove and discard the pinion seal.

Installation
1. Coat the new rear axle drive pinion seal lips with grease.





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 splines with rear axle lubricant.





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 readings 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 lbs.) 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.





8. Align the index marks.





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

Install the driveshaft.





10. Install the rear brake discs and calipers.





11. Install the rear wheel and tire assemblies.





12. Reactivate the air suspension system by turning on the switch.