Pinion Flange: Service and Repair

Drive Pinion Flange and Drive Pinion Seal





Special Tool(s)

Removal

1. CAUTION: Do not allow the calipers to hang from the brake hoses.

NOTE: Remove the rear wheels and the brake calipers to prevent drag during the drive pinion bearing preload adjustment.

Remove and secure the rear brake calipers aside.

2. CAUTION: Do not disconnect the driveshaft before referring to disconnect the driveshaft.

Remove the driveshaft assembly.





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





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





5. Remove and discard the pinion nut.
^ Install the special tool.
^ Install a suitable breaker bar and remove the nut.





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





7. Force up the metal flange of the rear axle drive pinion seal.





8. Clamp and strike the locking pliers with a hammer to remove the rear axle drive pinion seal.

Installation
1. Lubricate the lips of the new rear axle drive pinion seal.
^ Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-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 it and install a new one.





Using the special tool, install the rear axle drive pinion seal.
3. Lubricate the pinion flange splines.
^ Use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.

4. CAUTION: Inspect the pinion flange seal journal for rust or nicks/scratches prior to installing the pinion flange. Polish the seal journal with fine crocus cloth, if required.

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

Align the pinion flange with the drive pinion shaft.





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

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





Use the special tool to hold the pinion flange while tightening the new pinion nut.
^ Rotate the pinion occasionally to make sure the differential pinion bearings seat correctly. Take frequent differential pinion bearing torque preload readings by rotating the pinion with a Nm (inch-pound) torque wrench.





7. If the preload recorded prior to disassembly is lower than the specifications for used bearings, tighten the pinion nut to specifications. If the preload recorded prior to disassembly is higher than the specifications for used bearings, tighten the pinion nut to the original reading as recorded.
8. Connect the driveshaft.
9. Install the rear brake calipers.
10. Install the rear wheel and tire assemblies.