Pinion Flange: Service and Repair

Special Tools:

Removal

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

Note: Remove the rear wheels and the bake 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 Section 205-01.

Disconnect and position the driveshaft out of the way.





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. CAUTION: After removing the pinion nut, discard it. Use a new nut for installation.

Note: Make sure to insert the cotter key on the special tool as shown.

Remove the pinion nut.
1 Install the special tool.
2 Install a suitable breaker bar and remove the nut.





5. Mark the pinion flange in relation to the drive pinion stem to ensure correct alignment during installation.





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

Installation
1. Lubricate the pinion flange splines.
- Use SAE 75W140 Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.





2. CAUTION: Inspect the pinion Range 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.





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

4. 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.





Note: Make sure to insert the cotter key on the special tool as shown.

Use the special tool to hold the pinion flange while tightening the 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.





- If the preload recorded prior to disassembly is lower than the specification for used bearings, then tighten the pinion nut to specification. If the preload recorded prior to disassembly is higher than the specification for used bearings, then tighten the pinion nut to the original reading as recorded.
5. Connect the driveshaft.
6. Install the rear brake calipers.
7. Install the rear wheel and tire assemblies.