Drive Pinion Flange and Seal: Removal

WARNING: This page is about a different car, the 2005 Mercury Mountaineer and 2005 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: This operation disturbs the pinion bearing preload. Carefully reset the pinion bearing preload during assembly.

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING .

NOTE: The front wheels and tires and brake calipers must be removed to prevent drag during the pinion bearing preload recording and adjustment.

Remove the front tires and wheels. For additional information, refer to WHEELS AND TIRES .
Remove the front driveshaft. For additional information, refer to DRIVESHAFT .

CAUTION: When removing the disc brake caliper, never allow it to hang from the brake hose. Provide a suitable support.

Remove the disc brake caliper anchor bolts, then remove the disc brake caliper and disc brake caliper anchor as an assembly.
- Using mechanic's wire, position and support the disc brake caliper and disc brake caliper anchor.
  
  Fig 1: Removing Disc Brake Caliper Anchor Bolts
  Courtesy of FORD MOTOR CO.
Measure and record the pinion bearing preload.
- Using a Nm torque wrench, rotate the pinion gear. Measure the torque required to maintain pinion gear rotation.
  
  Fig 2: Checking Pinion Bearing Preload
  Courtesy of FORD MOTOR CO.
Index-mark the pinion flange and the pinion gear stem.

Fig 3: Aligning Pinion Flange And Pinion Gear Stem Index Marks
Courtesy of FORD MOTOR CO.
Using the special tool to hold the pinion flange, remove and discard the pinion nut and washer.

Fig 4: Identifying Pinion Flange Holding Tool
Courtesy of FORD MOTOR CO.
Using the special tool, remove the pinion flange.

Fig 5: Removing Pinion Flange
Courtesy of FORD MOTOR CO.
Inspect the pinion flange for burrs and damage. Inspect the end of the pinion flange that contacts the pinion bearing cone, pinion nut counterbore and drive pinion oil seal surface for nicks. Discard the pinion flange if damaged.
Using the special tool and a suitable slide hammer, remove the drive pinion oil seal.

Fig 6: Removing Drive Pinion Oil Seal
Courtesy of FORD MOTOR CO.
Remove the drive pinion oil slinger and the outer pinion bearing.

Fig 7: Identifying Outer Drive Pinion Bearing And Drive Pinion Shaft Oil Slinger
Courtesy of FORD MOTOR CO.
Remove and discard the collapsible spacer.
Verify the splines on the pinion stem are free of burrs. If burrs are evident, remove them with a fine crocus cloth.
Clean the drive pinion oil seal bore.