Removal and Installation

1. With the vehicle in NEUTRAL, position on a hoist. For additional information, refer to JACKING & LIFTING .
NOTE: The front wheels and tires and brake calipers must be removed to prevent drag during the drive pinion preload recording and adjustment.
2. Remove the front tires and wheels. For additional information, refer to SUSPENSION SYSTEM .
3. Remove the front disc brake calipers and position them aside. For additional information, refer to BRAKE SYSTEM .
CAUTION: Do not allow the driveshaft to hang unsupported.
4. Disconnect the front driveshaft from the pinion flange and position it aside. For additional information, refer to FRONT DRIVESHAFT .
5. Remove the parts in the order indicated in the following illustration and table.
   Fig 1: Removing Drive Pinion Flange And Drive Pinion Seal - Front Axle

   Courtesy of FORD MOTOR CO.
6. To install, reverse the removal procedure.
7. Check the lubricant level in the front axle assembly and, if necessary, fill the axle to specification.

Item 1: Pinion Nut and Washer Removal Note 

1. Measure and record the pinion bearing torque preload.
   • Using a Nm (inch-pound) torque wrench, rotate the pinion. Measure the torque required to maintain pinion rotation.
   Fig 2: Measuring Torque Required To Maintain Pinion Rotation

   Courtesy of FORD MOTOR CO.
2. Index-mark the pinion flange and the pinion stem.
   Fig 3: Indexing The Pinion Flange And The Pinion Stem

   Courtesy of FORD MOTOR CO.
3. Using the special tool to hold the pinion flange, remove and discard the pinion nut and washer.
   Fig 4: Removing And Discard Pinion Nut And Washer

   Courtesy of FORD MOTOR CO.

Item 2: Pinion Flange Removal Note 

1. Using the special tool, remove the pinion flange.
   Fig 5: Removing Pinion Flange

   Courtesy of FORD MOTOR CO.
2. Inspect the pinion flange for burrs and damage. Inspect the end of the pinion flange that contacts the bearing cone, nut counterbore and seal surface for nicks. Discard the pinion flange if damaged.

Item 3: Pinion Oil Seal Removal Note 

1. Using the special tool, remove the pinion seal.
   Fig 6: Using Special Tool, Removing Pinion Seal

   Courtesy of FORD MOTOR CO.
2. Verify the splines on the pinion stem are free of burrs. If burrs are evident, remove them with a fine crocus cloth.
3. Clean the pinion seal bore.

Item 3: Pinion Oil Seal Installation Note 

NOTE: Lubricate the pinion seal lips with axle lubricant.
NOTE: Pinion seal must be fully seated all the way around or pinion seal damage will occur.
Fig 7: Installing Pinion Seal
Courtesy of FORD MOTOR CO.
1. Using the special tool, install the pinion seal.

Item 2: Pinion Flange Installation Note 

CAUTION: Never use a hammer or install the flange with power tools.
NOTE: Lubricate the pinion flange splines.
Fig 8: Installing Pinion Flange
Courtesy of FORD MOTOR CO.
1. Align the index marks and using the special tool, install the pinion flange.

Item 1: Pinion Nut and Washer Installation Note 

1. Install the new washer and pinion nut. Only hand-tighten the nut at this time.
   Fig 9: Installing New Washer And Pinion Nut

   Courtesy of FORD MOTOR CO.
CAUTION: Do not loosen the nut to reduce preload. Install a new collapsible spacer and nut if preload reduction is necessary.
Fig 10: Holding Pinion Flange Using Special Tool
Courtesy of FORD MOTOR CO.
2. Using the special tool to hold the pinion flange, tighten the nut to set the preload.
   • Tighten the nut, rotating the pinion occasionally to make sure the differential pinion bearings are seating correctly. Take frequent differential pinion bearing preload readings by rotating the pinion with a Nm (inch-pound) torque wrench. The final reading must be 0.56 Nm (5 lb-in) more than the initial reading taken during removal.