Drive Pinion: Removal

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 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: Identifying Alignment Mark On Driveshaft Flange And Pinion Flange
Courtesy of FORD MOTOR CO.
Remove and discard the four bolts.

Fig 2: Identifying Index-Mark To Driveshaft And 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.

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.
  
  Fig 3: Disconnecting Driveshaft Flange Yoke From Pinion Flange
  Courtesy of FORD MOTOR CO.
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: Inspecting 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: Identifying 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 Assembly Out Of Front Pinion Bearing
Courtesy of FORD MOTOR CO.
Remove and discard the collapsible spacer.

Fig 7: Identifying Drive Pinion Collapsible Spacer
Courtesy of FORD MOTOR CO.
Using the special tool, remove the inner pinion bearing.

Fig 8: Removing Pinion Bearing Using Special Tool
Courtesy of FORD MOTOR CO.

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

Fig 9: Identifying 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.