Drive Pinion Seal: Removal

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

With the vehicle in NEUTRAL, position it on a hoist. Refer to JACKING & LIFTING .
Index-mark the front driveshaft and the front axle flange to maintain driveline balance.

Fig 1: Identifying Index-Mark On Front Driveshaft And Front Axle Flange
Courtesy of FORD MOTOR CO.
Disconnect the front driveshaft from the front axle flange and position it aside.
1. Remove and discard the four bolts and two retainers.
2. Disconnect the front driveshaft from the front axle flange.
3. Tape the bearing cups to the spider to prevent them from falling off the spider.
4. Position the driveshaft aside.
  
  Fig 2: Disconnecting Front Driveshaft From Front Axle Flange And Positioning It Aside
  Courtesy of FORD MOTOR CO.
Measure the pinion bearing torque preload. Record the reading.
- Rotate the pinion with a Nm (inch-pound) torque wrench. Record the torque necessary to maintain rotation of the pinion through several revolutions.
  
  Fig 3: Measuring Pinion Bearing Torque Preload
  Courtesy of FORD MOTOR CO.
Using the special tool, remove and discard the nut and washer.

Fig 4: Removing Flange Nut And Washer Using Special Tool
Courtesy of FORD MOTOR CO.

NOTE: Index-mark the flange and the pinion shaft.

Fig 5: Removing Flange Using Special Tool

Courtesy of FORD MOTOR CO.

Using the special tool, remove the flange.
Using the special tools, remove the pinion seal. Discard the seal.

Fig 6: Removing Pinion Seal Using Special Tool
Courtesy of FORD MOTOR CO.
Clean and inspect the following:
- The seal mounting surface.
- The flange lugs and the flange end that contacts the bearing cone.
  - Verify that the flange nut counterbore and the seal contact surfaces are smooth and free of nicks.