Drive Pinion: Removal

WARNING: This page is about a different car, the 2002 Ford RV Cutaway, 2002 Ford Econoline, 2002 Ford E550 Super Duty, 2002 Ford E450 Super Duty, and 2002 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

Remove differential case (4204). For additional information, refer to DIFFERENTIAL CASE .
Mark the driveshaft flange and the pinion flange for correct alignment during installation.

Fig 1: Marking Driveshaft Flange And Pinion Flange
Courtesy of FORD MOTOR CO.
Remove the four bolts.

Fig 2: Removing Four Bolts
Courtesy of FORD MOTOR CO.

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.

Fig 3: Disconnecting Driveshaft Centering Socket Yoke With Special Tool

Courtesy of FORD MOTOR CO.

Using a suitable tool as shown, disconnect the driveshaft centering socket yoke from the rear axle pinion flange.
- Position the driveshaft out of the way.
Install a Nm (inch-pound) torque wrench on the pinion nut, and record the torque required to maintain rotation of the pinion through several revolutions.

Fig 4: Measuring Pinion Rotational Torque
Courtesy of FORD MOTOR CO.
Remove the pinion flange and pinion nut. For additional information, refer to DRIVE PINION FLANGE .
Remove the rear axle drive pinion shaft oil slinger (4670).

Fig 5: Removing Rear Axle Drive Pinion Shaft Oil Slinger
Courtesy of FORD MOTOR CO.
Remove the rear axle drive pinion seal (4676). For additional information, refer to DRIVE PINION SEAL .
Using a soft-faced hammer and the special tool, drive the pinion out of the outer pinion bearing and remove the drive pinion through the rear of the housing.

Fig 6: Removing Drive Pinion Through Rear Of Housing
Courtesy of FORD MOTOR CO.
Remove and discard the collapsible spacer.

Fig 7: Removing Collapsible Spacer
Courtesy of FORD MOTOR CO.
Using the special tool, remove the pinion bearing cone and roller assembly.

Fig 8: Remove The Pinion Bearing Cone And Roller With Special Tool
Courtesy of FORD MOTOR CO.

NOTE: Do not remove the pinion bearing cups from the carrier casting unless the cups are damaged.

Fig 9: Removing Outer Differential Bearing Cup With Special Tool

Courtesy of FORD MOTOR CO.

Using the special tools, remove the outer differential bearing cup.
Using the special tools, remove the inner differential bearing cup.

Fig 10: Removing Inner Differential Bearing Cup With Special Tool
Courtesy of FORD MOTOR CO.