Output Shaft Seal: Installation

All vehicles 

• 1.
  
  Install the new collapsible spacer.

Courtesy of FORD MOTOR COMPANY

• 2.
  
  Install the outer pinion bearing.

Courtesy of FORD MOTOR COMPANY

• 3.
  
  Install the oil slinger.

Courtesy of FORD MOTOR COMPANY

• 4.
  
  Using the 308-430, install the new output shaft seal.

Courtesy of FORD MOTOR COMPANY

• 5.
  
  
  NOTE: Install the output pinion flange to engage the spline as previously marked. Install a new output pinion flange and deflector if the output shaft seal mating surface is damaged.

  Install the output pinion flange.

Courtesy of FORD MOTOR COMPANY

• 6.
  
  
  NOTE: Refer to the rotational torque previously recorded with the Nm (lb-in) torque wrench. Tighten the pinion nut in small increments until it is within 0.3 Nm (3 lb-in) of the reference measurement. If 0.3 Nm (3 lb-in) is exceeded, then the collapsible spacer will be damaged and a new collapsible spacer will be required.

  Using the 205-126 T78P-4851-A to hold the output pinion flange, install and tighten the new pinion flange nut.

Courtesy of FORD MOTOR COMPANY

• 7.
  
  
  NOTE: Line up the index marks on the rear driveshaft to the index marks on the PTU flange made during removal.
  • Tighten to 70 Nm (52 lb-ft).

Courtesy of FORD MOTOR COMPANY

GTDI vehicles 

• 8.
  
  Install the new LH and RH exhaust flexible pipe-to-underbody catalytic converter gaskets and nuts.
  • Tighten to 40 Nm (30 lb-ft).

All vehicles except GTDI 

• 9.
  
  Install the new exhaust Y-pipe-to-muffler and tail pipe flange gasket and nuts.
  • Tighten to 40 Nm (30 lb-ft).

All vehicles 

• 10.
  
  Install the front subframe. Refer to Uni-Body, Subframe and Mounting System .

• 11.
  
  Fill the PTU as necessary. Refer to Power Transfer Unit (PTU) Draining and Filling .