Dana S110 and S130 Rear Axle Pinion Assembly, Disassembled View: Disassembly

WARNING: This page is about a different car, the 2013 Ford F-550 Super Duty, 2013 Ford F-450 Super Duty, 2013 Ford F-350 Super Duty, and 2013 Ford F-250 Super Duty. 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 AND RING GEAR .
Remove the pinion hex nut.

Fig 1: Locating Pinion Hex Nut
Courtesy of FORD MOTOR CO.
NOTE: Hammering on the pinion flange will close in the bearing bores and misalign the flange lugs. This will result in premature failure of the journal needle bearings. Serious damage will also occur internally to the differential ring gear and pinion set or pinion bearings by hammering on external parts. Remove and install the pinion flange using only the procedures in this article.

Using the Yoke Remover, remove the pinion flange.

Fig 2: Removing Pinion Flange Using Special Tool
Courtesy of FORD MOTOR CO.
Remove the pinion seal.

Fig 3: Locating Pinion Seal
Courtesy of FORD MOTOR CO.
NOTE: Position a block of wood under the pinion to avoid damage to the gear teeth.

NOTE: The outer bearing is press fit.

Press the pinion through the outer pinion bearing and remove the pinion.

Fig 4: Pressing Pinion Through Outer Pinion Bearing
Courtesy of FORD MOTOR CO.
Remove the pinion preload spacer.
- Measure and record the spacer thickness. Set the spacer aside for use in assembly.
  
  Fig 5: Locating Pinion Preload Spacer
  Courtesy of FORD MOTOR CO.
If reusing the gear set, remove the inner pinion bearing with a suitable puller.

Fig 6: Locating Inner Pinion Bearing
Courtesy of FORD MOTOR CO.
If new pinion bearings are being installed, remove the outer and inner pinion bearing cups.

Fig 7: Locating Outer And Inner Pinion Bearing Cups
Courtesy of FORD MOTOR CO.
NOTE: Alkaline cleaning solutions will damage machine surfaces. Use only emulsion cleaners or petroleum-based cleaning solvent.

NOTE: Use soft, clean, lintless towels to dry the components.

NOTE: After drying, lightly coat the parts with rust inhibitor or clean lubricant to prevent damage from corrosion. Wrap all parts that are going to be in storage for a prolonged period in wax paper.

Clean and dry the components as necessary.
Inspect the pinion flange for grooves in the sealing surface caused by contamination.
- If grooves are detectable with a fingernail, repair the flange with a Chicago Rawhide approved sleeve or install a new flange.
  
  Fig 8: Inspecting Pinion Flange For Grooves In Sealing Surface
  Courtesy of FORD MOTOR CO.