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Home >> Mercury >> 2009 >> Mariner Base, 2.5 7, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 23 (Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear) >> In-Vehicle Servicing >> Drive Pinion Flange and Drive Pinion Seal >> Installation

Drive Pinion Flange and Drive Pinion Seal: Installation

WARNING: This page is about a different car, the 2009 Ford Mustang. However, it is still accessible from the selected car via links, so may be relevant.
  1. Lubricate the new drive pinion seal with grease.
    2. NOTE: If the new drive pinion seal becomes misaligned during installation, remove the drive pinion seal and install a new drive pinion seal.
  2. Using the special tool, install a new drive pinion seal.
    3. Fig 1: Using Special Tool (205-208) To Install Drive Pinion Seal
    G03878608Courtesy of FORD MOTOR CO.
  3. Lubricate the pinion flange splines with axle lubricant.
    4. NOTE: Disregard the scribe marks if a new pinion flange is being installed.
  4. Align the pinion flange with the drive pinion shaft.
    5. Fig 2: Identifying Index-Mark On Drive Pinion Stem
    GF0015352Courtesy of FORD MOTOR CO.
  5. Using the special tool, install the pinion flange.
    6. Fig 3: Installing Pinion Flange Using Special Tool 205-002
    GF0015354Courtesy of FORD MOTOR CO.
    CAUTION: The color on the rear face of the drive pinion nut is critical to this repair. 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.
  6. Using the chart below, determine the pinion nut to be installed.
    8.8-INCH DRIVE PINION NUT

    Part Number Color Description Application
    19G405 Orange/Yellow Axles built before 7/16/07
    4320 Purple Axles built after 7/16/07
    4C121 Purple Kit with spacer for all 8.8-in axles
  7. Position the new pinion nut.
    8. NOTE: Under no circumstances is the pinion nut to be backed off to reduce drive pinion bearing preload. If reduced drive pinion bearing preload is required, a new drive pinion collapsible spacer and pinion nut kit must be installed.
    NOTE: Remove the special tool while taking drive pinion bearing preload readings with the Nm (lb-in) torque wrench.
  8. Using the special tool to hold the pinion flange, tighten the pinion nut.
    • Rotate the drive pinion occasionally to make sure the drive pinion bearings are seating correctly.
    • Install a Nm (lb-in) torque wrench on the pinion nut.
    • Rotating the drive pinion through several revolutions, take frequent drive pinion bearing preload readings until the original recorded drive pinion bearing preload reading is obtained.
    • If the original recorded drive pinion bearing preload is lower than specifications, tighten to the specification. If the drive pinion bearing preload is higher than specification, tighten the pinion nut to the original reading as recorded. For additional information, refer to the SPECIFICATIONS .
  9. Install the driveshaft. For additional information, refer to DRIVESHAFT .
  10. Install the rear brake disc. For additional information, refer to REAR DISC BRAKE .
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