Drive Pinion: Removal

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Remove the differential case. Refer to DIFFERENTIAL CASE .
Index-mark the driveshaft at the axle flange.

Fig 1: Identifying Index Mark
Courtesy of FORD MOTOR CO.
Remove and discard the bolts.

Fig 2: Removing And Discard Bolts
Courtesy of FORD MOTOR CO.

CAUTION: After removal of the pinion nut, discard it. A new nut must be used for installation.

Fig 3: Removing Pinion Nut

Courtesy of FORD MOTOR CO.

Using the special tool, remove the pinion nut.
Index-mark the drive pinion flange and the pinion shaft.

Fig 4: Identifying Mark Drive Pinion Flange And Pinion Shaft
Courtesy of FORD MOTOR CO.
Using the special tool, remove the pinion flange.

Fig 5: Removing Pinion Flange
Courtesy of FORD MOTOR CO.
Force up on the metal flange of the rear axle drive pinion seal. Install gripping pliers to the seal flange and strike with a hammer until the rear axle drive pinion seal is removed.
- Remove the oil slinger and the outer pinion bearing.
  
  Fig 6: Removing Oil Slinger And Outer Pinion Bearing
  Courtesy of FORD MOTOR CO.
Install the special tool and, with a soft-faced hammer, drive the pinion out of the front bearing cone and remove it through the rear of the housing.

Fig 7: Installing Special Tool And, With A Soft-Faced Hammer
Courtesy of FORD MOTOR CO.

NOTE: Remove the collapsible spacer and discard it.

Fig 8: Removing Pinion Bearing

Courtesy of FORD MOTOR CO.

Use the special tool to remove the pinion bearing.

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

NOTE: Tap alternately on opposite sides of the cups to prevent them from cocking in the bore.

Fig 9: Removing Differential Bearing Cups

Courtesy of FORD MOTOR CO.

Use a suitable brass drift to remove the differential bearing cups.