Drive Pinion: Removal

WARNING: This page is about a different car, the 2004 Ford RV Cutaway, 2004 Ford Econoline, 2004 Ford E450 Super Duty, and 2004 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

Remove the differential case. 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 For Correct Alignment During Installation
Courtesy of FORD MOTOR CO.
Remove and discard the four bolts.

Fig 2: Removing Driveshaft Flange 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 From Rear Axle Pinion Flange

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: Identifying Torque Required To Maintain Rotation Of Pinion
Courtesy of FORD MOTOR CO.
Remove the pinion flange and pinion nut. For additional information, refer to DRIVE PINION FLANGE .
- Discard the pinion nut.
Remove the rear axle drive pinion shaft oil slinger.

Fig 5: Removing Rear Axle Drive Pinion Shaft Oil Slinger
Courtesy of FORD MOTOR CO.
Remove the rear axle drive pinion seal. 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: Driving Pinion Out Of Outer Pinion Bearing
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 inner pinion bearing.

Fig 8: Removing Inner Pinion Bearing
Courtesy of FORD MOTOR CO.

NOTE: Do note remove the pinion bearing cups from the carrier casting unless the cups are damaged.

Fig 9: Removing Pinion Bearing Cups

Courtesy of FORD MOTOR CO.

Using a brass drift, remove the pinion bearing cups by tapping alternately on opposite sides of the cups.