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Drive Pinion Flange: Installation

WARNING: This page is about a different car, the 2007 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
  1. Lubricate the pinion flange splines with rear axle lubricant.
    2. Fig 1: Placing Index Marks On Pinion Flange
    GF0000818Courtesy of FORD MOTOR CO.
    NOTE: Disregard the scribe marks if a new pinion flange is being installed.
  2. Align the pinion flange with the drive pinion shaft.
    3. Fig 2: Installing Pinion Flange Using Special Tool (205-002)
    GF0003074Courtesy of FORD MOTOR CO.
    NOTE: Disregard the scribe marks if a new pinion flange is being installed.
  3. Using the special tool, install the pinion flange.
    4. Fig 3: Identifying Pinion Nut
    GF0000819Courtesy of FORD MOTOR CO.
    CAUTION: Use the same color new drive pinion nut for installation. If a new collapsible spacer must be installed for pinion bearing preload reduction, install the nut supplied with the new spacer or damage to the component may occur.
  4. Position the new pinion flange nut.
    8.8 IN DRIVE PINION NUT

    Part Number Color Application
    389546-S100 Orange Axles built before 7/16/07
    4320 Purple Axles built after 7/16/07
    4C121 Purple Kit with spacer all 8.8 in
    5. Fig 4: Holding Pinion Flange Using Special Tool
    G03878592Courtesy of FORD MOTOR CO.
    CAUTION: Do not, under any circumstance, loosen the nut to reduce preload. If it is necessary to reduce preload, install a new collapsible spacer and nut kit or damage to the component may occur.
    NOTE: Remove the special tool while taking preload readings with the N.m (lb-in) torque wrench.
  5. Using the special tool to hold the pinion flange, tighten the nut.
    • Rotate the pinion occasionally to make sure the differential pinion bearings seat correctly. Take frequent differential pinion bearing preload readings by rotating the pinion with a N.m (lb-in) torque wrench.
    • If the preload recorded prior to disassembly is lower than the specification, tighten the nut to specification. If the preload recorded prior to disassembly is higher than the specification, tighten the nut to the original reading as recorded.
    6. Fig 5: Locating Driveshaft Flange Bolts
    GF0000834Courtesy of FORD MOTOR CO.
    NOTE: Align the index marks.
    NOTE: If new bolts to retain the driveshaft to the axle are not available, coat the threads of the original bolts with threadlock.
    NOTE: The driveshaft flange fits tightly on the rear axle pinion flange pilot. To make sure that the driveshaft flange seats squarely on the pinion flange, tighten the bolts evenly in a cross pattern.
  6. Position the driveshaft flange on the pinion flange with the index marks aligned, and install the bolts.
    • Tighten to 112 Nm (83 lb-ft).
  7. Install the brake drums. For additional information, refer to DRUM BRAKE .
  8. Install the rear wheel and tire. For additional information, refer to WHEELS AND TIRES .
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