Pinion Flange: Service and Repair

Special Tools And Equipment:

Special Tool(s)

Removal
1. Raise and support the vehicle.
2. Remove the rear wheel and tire assemblies.

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

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

Remove the rear brake caliper and support bracket from the knuckle as an assembly. Wire the caliper and support bracket assembly out of the way.

Part 1 Of 2:

Part 2 Of 2:

4. CAUTION: Index-mark the driveshaft flange and rear axle pinion flange to maintain initial balance during installation.

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.

Disconnect and position the driveshaft out of the way.





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





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

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





7. Index-mark the rear axle pinion flange and drive pinion gear stem to maintain mutual balance during installation.





8. Using the special tool, remove the rear axle pinion flange.

Installation
1. Inspect the rear axle pinion flange seal journal for rust, nicks, and scratches prior to installing the flange. Polish the seal journal with fine crocus cloth, if necessary.
2. Lubricate the rear axle pinion flange splines.
^ Use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.





3. NOTE: Disregard the index marks if installing a new rear axle pinion flange.

Position the rear axle pinion flange.





4. Using the special tools, install the rear axle pinion flange.





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

Tighten the nut to set the preload.
^ Rotate the pinion occasionally to make sure the pinion bearings seat correctly. Take frequent pinion bearing torque preload readings by rotating the drive pinion gear 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 nut to specification. If the preload recorded prior to disassembly is higher than the specification for used bearings, then tighten the nut to the original reading as recorded.
^ Refer to the torque specification for used pinion bearings Specifications.





6. CAUTION: Align the index-marks.

CAUTION: Install the driveshaft with new bolts. If new bolts are not available, apply Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5 to the threads of the original bolts.

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.

Connect the driveshaft.
7. Install the rear brake calipers.
8. Install the rear wheel and tire assemblies.
9. Lower the vehicle.