Removal and Installation

1. With the vehicle in NEUTRAL, position on a hoist. For additional information, refer to JACKING & LIFTING .
2. Remove the rear wheel and tire assemblies. For additional information, refer to SUSPENSION SYSTEM .
CAUTION: Remove the rear brake calipers to prevent drag during the drive pinion bearing preload adjustment.
CAUTION: Do not remove the guide pins or guide pin boots unless a problem is suspected. The guide pins are meant to be sealed for life and are not repairable. Use Silicone Brake Caliper Grease and Dielectric Compound or equivalent for re-lubing the caliper slide pins. Other greases can swell the guide pin boots, resulting in contamination and accelerated corrosion and wear of the caliper slide pin mechanism.
CAUTION: Do not allow the calipers to hang from the brake hoses.
Fig 1: Removing Rear Disc Brake Caliper Assembly
Courtesy of FORD MOTOR CO.
3. Remove the rear disc brake caliper assembly.
   1. Remove the caliper bolts.
   2. Lift the rear disc brake caliper off the knuckle.
      • Support the caliper assembly with a length of mechanic's wire.
CAUTION: Index-mark the driveshaft flange and rear axle pinion flange for correct alignment during installation.
Fig 2: Removing Driveshaft Bolts
Courtesy of FORD MOTOR CO.
4. Remove the four bolts.
CAUTION: The driveshaft flange fits tightly on the rear axle pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft flange from the pinion flange. Pry only in the area shown, with a suitable tool, to disconnect the driveshaft flange from the pinion flange.
Fig 3: Disconnecting Driveshaft Flange From Rear Axle Flange
Courtesy of FORD MOTOR CO.
5. Using a suitable tool as shown, disconnect the driveshaft flange from the rear axle flange, and position and secure the driveshaft aside.
6. Remove the parts in the order indicated in the following illustration and table.
   Fig 4: Removing Drive Pinion Flange And Drive Pinion Seal - Rear Axle

   Courtesy of FORD MOTOR CO.
CAUTION: To prevent interference with the rear disc brake caliper operation, install only the correct caliper bolt.
NOTE: Make sure the stainless steel shoe slippers are correctly positioned. Install new slippers if worn or damaged
NOTE: Use the disc brake pad spreader to spread pads for reassembly.
Fig 5: Installing Brake Caliper
Courtesy of FORD MOTOR CO.
7. To install, reverse the removal procedure.
CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion flange pilot. To make sure that the yoke seats squarely on the flange, tighten the bolts evenly in a cross patter as shown.
CAUTION: If new bolts to retain the driveshaft to the axle flange are not available, coat the threads of the original bolts with Threadlock and Sealer.
Fig 6: Tightening Driveshaft Bolts
Courtesy of FORD MOTOR CO.
8. Fill the axle with the specified quantity of the specified lubricant. For additional information, refer to the SPECIFICATIONS .

Item 1: Pinion Nut Removal Note 

1. Install a Nm (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 7: Measuring Pinion Gear Rotational Torque

   Courtesy of FORD MOTOR CO.
CAUTION: After removing the nut, discard it. Always use a new nut for installation.
Fig 8: Removing Pinion Nut Use Special Tool
Courtesy of FORD MOTOR CO.
2. Use the special tool to hold the rear axle pinion flange while removing the nut.

Item 2: Rear Axle Pinion Flange Removal Note 

1. Index-mark the rear axle pinion flange and drive pinion gear to maintain initial balance during installation.
   Fig 9: Identifying Index-Mark On Rear Axle Pinion Flange And Pinion Gear

   Courtesy of FORD MOTOR CO.
2. Using the special tool, remove the rear axle pinion flange.
   Fig 10: Removing Rear Axle Pinion Flange Using Special Tool

   Courtesy of FORD MOTOR CO.

Item 3: Rear Pinion Oil Seal Removal Note 

1. 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 11: Removing Rear Axle Drive Pinion Seal

   Courtesy of FORD MOTOR CO.

Item 3: Rear Pinion Oil Seal Installation Note 

1. 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 12: Installing Rear Axle Drive Pinion Seal Using The Special Tool
Courtesy of FORD MOTOR CO.
2. Using the special tool, install the rear axle drive pinion seal.

Item 2: Rear Axle Pinion Flange Installation Note 

1. 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.
2. Lubricate the rear axle pinion flange splines.
NOTE: Disregard the index marks if installing a new rear axle pinion flange.
Fig 13: Positioning Rear Axle Pinion Flange
Courtesy of FORD MOTOR CO.
3. Position the rear axle pinion flange.
4. Using the special tools, install the rear axle pinion flange.
   Fig 14: Tightening Rear Axle Pinion Flange Nut Using Special Tools

   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.
Fig 15: Measuring Pinion Rotational Torque
Courtesy of FORD MOTOR CO.
1. 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 Nm (inch-pound) torque wrench.
   • Refer to the TORQUE SPECIFICATION  for used pinion bearings in the Specifications.