Drive Pinion Flange and Drive Pinion Seal: Removal

WARNING: This page is about a different car, the 2003 Ford RV Cutaway, 2003 Ford Econoline, 2003 Ford E550 Super Duty, 2003 Ford E450 Super Duty, and 2003 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

Raise the vehicle on a hoist or raise the rear end of the vehicle with a jack. Install safety stands under the frame rails and lower the jack or hoist enough to allow the rear axle to drop into the rebound position for working clearance.
Index-mark the driveshaft flange and the pinion flange to maintain driveline balance during assembly.

Fig 1: Identifying Mark On Driveshaft Flange And Pinion Flange
Courtesy of FORD MOTOR CO.
Remove the four bolts.

Fig 2: Removing Four Driveshaft Flange Bolts
Courtesy of FORD MOTOR CO.

CAUTION: The driveshaft flange fits tightly on the 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 Yoke From Pinion Flange

Courtesy of FORD MOTOR CO.

Using a suitable tool as shown, disconnect the driveshaft flange yoke from the pinion flange and position the driveshaft aside.

CAUTION: Index-mark the pinion flange to the pinion shaft prior to removal.

Fig 4: Removing Lock Nut And Washer With Special Tool

Courtesy of FORD MOTOR CO.

Use the special tool to prevent the flange from turning while removing the lock nut and washer.
Using the special tool, remove the pinion flange.

Fig 5: Removing Pinion Flange With Special Tool
Courtesy of FORD MOTOR CO.
Using the special tools, remove and discard the pinion seal.

Fig 6: Removing Pinion Seal With Special Tool
Courtesy of FORD MOTOR CO.
Clean the pinion seal seat.