Pinion Flange: Service and Repair

Drive Pinion Flange and Drive Pinion Seal

















Removal

1. WARNING: Before servicing a vehicle equipped with a fire suppression system, depower the system by following the procedure in Fire Suppression System. Failure to follow the instructions may result in serious personal injury. Procedures

NOTE: 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 brake discs. For additional information, refer to Rear Disc Brake Brake Disc.

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





3. Remove the 4 driveshaft flange bolts.





4. NOTICE: 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 or damage to the component may occur.

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

- Position the driveshaft aside.





5. Install a Nm (lb-in) torque wrench on the nut and record the torque necessary to maintain rotation of the pinion through several revolutions.





6. Use the Drive Pinion Flange Holding Fixture to hold the pinion flange while removing the nut.
- Discard the nut.





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





8. Using the 2 Jaw Puller, remove the pinion flange.





9. Force up on the metal flange of the drive pinion seal. Install gripping pliers and strike with a hammer until the drive pinion seal is removed.
- Discard the seal.





Installation

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

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

Using the Drive Pinion Oil Seal Installer, 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 Drive Pinion Flange Installer, install the pinion flange.





6. Position the new drive pinion nut.





7. NOTICE: Do not, under any circumstance, loosen the nut to reduce preload or component damage may occur. If it is necessary to reduce preload, install a new collapsible spacer and nut.

NOTE: Remove the Drive Pinion Flange Holding Fixture while taking preload readings with the Nm (lb-in) torque wrench.

Use the Drive Pinion Flange Holding Fixture 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 (lb-in) torque wrench.

- If the preload recorded prior to disassembly is lower than the specification, tighten the nut to specification. If the preload recorded prior to disassembly is higher than the specification, tighten the nut to the original reading as recorded.





8. Align the index marks.





9. NOTE: 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.

Position the driveshaft and install the 4 bolts.

- Tighten to 112 Nm (83 lb-ft).





10. Install the brake discs. For additional information, refer to Rear Disc Brake Brake Disc.

11. WARNING: If the vehicle is equipped with a fire suppression system, repower the system. For important safety warnings and procedures, refer to Fire Suppression System. Failure to follow these instructions may result in serious personal injury. Description and Operation

Repower the system.