Removal & Installation
Remove and secure the rear brake calipers aside.
WARNINGOnly remove the flex couplings from the driveshaft if it is necessary to install new flex couplings/alignment bushings. Install new alignment bushings and flex couplings as a pair. Balance the driveshaft with the flex couplings installed.
WARNINGTo ensure assembly in the exact same location, index-mark the bolt, nut, washer, flex coupling and pinion flange with paint or marker. Using a different color paint or marker, index-mark the second bolt, nut and washer that retain the driveshaft and flex coupling to the pinion flange and the transmission flange. Do not index-mark the third bolt, nut, and washer that retain the driveshaft and flex coupling to the pinion flange. These fasteners are balance weights. Always assemble them in their original positions. Failure to do so can cause driveshaft imbalance.
- Remove the driveshaft assembly.
- Install a inch-pound torque wrench on the pinion nut and record the torque necessary to maintain rotation of the drive pinion gear through several revolutions.
- Mark the pinion flange in relation to the drive pinion stem to make sure of correct alignment during installation.
- Remove and discard the pinion nut.
- Install the special tool.
- Counter-hold the pinion flange with a suitable breaker bar and remove the nut.
Using the special tool, remove the pinion flange.
Force up the metal flange of the rear axle drive pinion seal.
Clamp and strike the locking pliers with a hammer to remove the rear axle drive pinion seal.
Lubricate the lips of the new rear axle drive pinion seal.
Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.
WARNINGInstallation without the correct tool can result in early seal failure.
WARNINGIf the rear axle drive pinion seal becomes misaligned during installation, remove it and install a new one.
- Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.
Using the special tool, install the rear axle drive pinion seal.
Lubricate the pinion flange splines.
Use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.
WARNINGInspect the pinion flange seal journal for rust or nicks/scratches prior to installing the pinion flange. Polish the seal journal with fine crocus cloth, if required.
NOTEDisregard the alignment marks if installing a new pinion flange.
- Use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.
- Align the pinion flange with the drive pinion shaft.
Using the special tools, install the pinion flange.
WARNINGDo not under any circumstance loosen the pinion nut to reduce preload. If it is necessary to reduce preload, install a new collapsible spacer and pinion nut.
Use the special tool to hold the pinion flange while tightening the new pinion nut.
- Rotate the pinion occasionally to make sure the differential pinion bearings seat correctly. Take frequent differential pinion bearing torque preload readings by rotating the pinion with a inch-pound torque wrench.
If the preload recorded prior to disassembly is lower than the specifications for used bearings, tighten the pinion nut to specifications. If the preload recorded prior to disassembly is higher than the specifications for used bearings, tighten the pinion nut to the original reading as recorded.
- 16-29 inch lbs (1.8-3.2 Nm)
- Connect the driveshaft.
- Install the rear brake calipers.
- Install the rear wheel and tire assemblies.