7.5-Inch Ring Gear
REMOVALSpecial Tools:
Replacement of rear axle drive pinion seal only involves removal and installation of pinion nut and rear axle universal joint flange.
1. CAUTION: This operation disturbs the pinion bearing preload. This preload must be carefully reset when assembling.
Raise the vehicle and install safety stands. Remove rear wheels.
2. Draw marks on the driveshaft centering socket yoke and rear axle universal joint flange for proper positioning of the driveshaft during assembly. Disconnect the driveshaft from the rear axle universal joint flange. Remove the driveshaft from the transmission extension housing. Install an oil seal replacer tool in the transmission extension housing to prevent oil leakage.
3. Install a Nm (inch lbs.) torque wrench on the pinion nut. Record torque required to maintain rotation of the pinion through several revolutions.
4. While holding rear axle universal joint flange with Companion Flange Holding Tool 205-126 (T78P-4851-A), remove pinion nut.
5. Clean area around rear axle drive pinion seal. Place a drain pan under rear axle drive pinion seal or raise front of vehicle higher than rear.
6. Mark rear axle universal joint flange in relation to pinion shaft so rear axle universal joint flange can be installed in same position.
7. CAUTION: Never remove the rear axle universal joint flange with a hammer.
Remove rear axle universal joint flange, using 2-Jaw Puller D97L-4221-A or equivalent.
8. CAUTION: Do not damage rear axle housing while removing rear axle drive pinion seal.
Position screwdriver under flange of rear axle drive pinion seal and strike with hammer to wedge screwdriver blade between metal flange of rear axle drive pinion seal and rear axle housing.
9. Pry up on metal flange of rear axle drive pinion seal. Install gripping pliers and strike with hammer until rear axle drive pinion seal is removed.
INSTALLATION
1. CAUTION: Installation without proper tool may result in early rear axle drive pinion failure. If rear axle drive pinion seal becomes cocked during installation, remove and replace with new rear axle drive pinion seal.
Clean the rear axle drive pinion seat surface and install rear axle drive pinion seal on Pinion Seal Replacer 205-133 (T79P-4676-A) and install rear axle drive pinion seal in rear axle housing. If not pre-greased, apply Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-13 between the lips of the rear axle drive pinion seal.
2. Make sure splines on the pinion shaft are free of burrs. If burrs are evident, remove them by using a fine crocus cloth. Working in a rotating motion, wipe the pinion clean.
3. Install rear axle drive pinion seal in rear axle housing.
4. Apply a small amount of SAE 8OW-90 Premium Rear Axle Lubricant XY-80W90-KL or OL or equivalent meeting Ford specification WSP-MC197-A to rear axle universal joint flange splines.
5. CAUTION: The rear axle universal joint flange must never be hammered on or assembled with power tools.
NOTE: Check rear axle universal joint flange for burrs. Remove burrs as necessary.
Align mark on the rear axle universal joint flange with the mark on the pinion shaft. Install rear axle universal joint flange.
6. Install a new nut on pinion shaft. Apply a small amount of SAE 8OW-90 Premium Rear Axle Lubricant XY-8OW90-KL or QL or equivalent meeting Ford specification WSP-MC197-A on the washer side of nut.
7. Hold the rear axle universal joint flange with Companion Flange Holding Tool 205-126 (T78P-4851-A) while tightening the nut.
8. Rotate pinion occasionally to provide proper bearing seating. Take frequent pinion bearing torque preload readings while tightening until the original recorded preload reading is obtained.
9. If the original recorded preload is less than specification, tighten to specification. If the preload is higher than specification, tighten to original reading as recorded.
Never back off the pinion nut to reduce preload. If reduced preload is required, a new differential drive pinion collapsible spacer and pinion nut should be installed.
10. Remove oil seal replacer tool from the transmission extension housing. Install front end of driveshaft on the transmission output shaft.
11. Connect the rear end of the driveshaft to the rear axle universal joint flange, aligning the scribe marks on the driveshaft and rear axle universal joint flange. Tighten the four bolts to 95-130 Nm (70-95 ft. lbs.).
12. CAUTION: Overfilling axles may cause seal and axle leakage.
Fill axle lubricant until it is 6-14 mm (1/4-9/16 inch) below the bottom of the fill hole with the axle in operating position. Do not exceed this level. Install filler plug. Tighten to 20-41 Nm (15-30 ft. lbs.).
13. Make sure rear axle housing vent is not plugged with debris.