Drive Pinion Flange and Drive Pinion Seal: Procedure

WARNING: This page is about a different car, the 2004 Lincoln LS. However, it is still accessible from the selected car via links, so may be relevant.

With the vehicle in NEUTRAL, position on a hoist.
Remove the rear wheel and tire assemblies.

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 out of the way. For additional information, refer to BRAKE SYSTEM .
Remove the driveshaft assembly.
Remove the components in the order indicated in the following illustration and table.
To install, reverse the removal procedure.

Fig 1: Removing/Installing Drive Pinion Flange And Drive Pinion Seal
Courtesy of FORD MOTOR CO.
Fill the axle with the specified quantity of the specified lubricant.

Item 1: Pinion Nut Removal Note

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

Fig 2: Installing N.m (Inch-Pound) Torque Wrench On Pinion Nut
Courtesy of FORD MOTOR CO.

CAUTION: After removing the nut, discard it. Always use a new nut for installation.

Fig 3: Removing Rear Axle Pinion Flange Nut

Courtesy of FORD MOTOR CO.

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

Item 2: Rear Axle Pinion Flange Removal Note

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

Fig 4: Marking Rear Axle Pinion Flange
Courtesy of FORD MOTOR CO.
Using the special tool, remove the rear axle pinion flange.

Fig 5: Removing Rear Axle Pinion Flange
Courtesy of FORD MOTOR CO.

Item 3: Rear Pinion Oil Seal Removal Note

Use a screwdriver to force up the metal flange of the rear axle drive pinion seal. Install gripping pliers and strike with a hammer to remove the rear axle drive pinion seal.

Fig 6: Removing Rear Axle Drive Pinion Seal
Courtesy of FORD MOTOR CO.

Item 3: Rear Pinion Oil Seal Installation Note

Lubricate the lips of the new seal with grease.

CAUTION: If the rear axle drive pinion seal becomes misaligned during installation, remove the seal and install a new one.

Fig 7: Installing Rear Axle Drive Pinion Seal

Courtesy of FORD MOTOR CO.

Using the special tool, install the rear axle drive pinion seal.

Item 2: Rear Axle Pinion Flange Installation Note

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.
Lubricate the rear axle pinion flange splines.

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

Position the index marks on the rear axle pinion flange.
Using the special tools, install the rear axle pinion flange.

Fig 8: Installing Rear Axle Pinion Flange
Courtesy of FORD MOTOR CO.

Item 1: Pinion Nut Installation Note

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 N.m (inch-pound) torque wrench.
- If the preload recorded prior to disassembly is lower than the specification for used bearings, tighten the nut to specification. If the preload recorded prior to disassembly is higher than the specification for used bearings, tighten the nut to the original reading as recorded.
- Refer to the torque specification for used pinion bearings in the Specifications portion of this section.
  
  Fig 9: Tightening Rear Axle Pinion Flange Nut
  Courtesy of FORD MOTOR CO.