8.8-Inch Ring Gear
REMOVALSpecial Tools:
NOTE: Replacement of rear axle drive pinion seal only involves removal and installation of the 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 the rear wheels.
2. Make scribe marks on driveshaft centering socket yoke and rear axle universal joint flange for proper position of driveshaft during assembly. Disconnect driveshaft from rear axle universal joint flange. Remove driveshaft from the transmission extension housing. Install oil seal replacer tool 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 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 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. Remove rear axle universal joint flange using Companion Flange Remover 205-018 (T65L-4851-B).
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: Installing without proper tool may result in early flange yoke seal failure. If rear axle drive pinion seal becomes cocked during installation, remove and replace with new rear axle drive pinion seal.
Clean flange yoke seat surface and install rear axle drive pinion seal on Pinion Seal Replacer 205-133 (T79P-4676-A). Apply Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C76-13 between rubber seal lips if rear axle drive pinion seal is not pre-greased.
2. NOTE: Check rear axle universal joint flange for burrs. Remove burrs as necessary.
Make sure splines on pinion shaft are free of burrs. If burrs are evident, remove them using a fine crocus cloth. Working in a rotating motion, wipe pinion clean.
3. Install rear axle drive pinion seal in rear axle housing.
4. Apply small amount of SAE 8OW-90 Premium Rear Axle Lubricant XY-80W90-01 meeting Ford specification WSP-M2C197-A to rear axle universal joint flange splines.
5. CAUTION: The circular rear axle universal joint flange must never be hammered on or assembled with power tools.
Align mark on rear axle universal joint flange with mark on pinion shaft. Install rear axle universal joint flange.
6. Install a new pinion nut on pinion shaft (apply small amount of lubricant on washer side of nut).
7. Hold the circular rear axle universal joint flange with Companion Flange Holding Tool 205-126 (T78P-4851-A) while tightening nut.
8. Rotate pinion occasionally to make sure proper bearing seating. Take frequent pinion bearing torque preload readings while tightening, until original recorded preload reading is obtained.
9. If original recorded preload is less than specification, tighten to specification. If preload is higher than specification, tighten to original reading as recorded.
Never back off pinion nut to reduce preload. If reduced preload is required, install new differential drive pinion collapsible spacer and pinion nut.
10. Remove oil seal replacer tool from transmission extension housing. Install front end of driveshaft on transmission output shaft.
11. Connect rear end of driveshaft to rear axle universal joint flange, aligning scribe marks on 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 with SAE 8OW-90 Premium Rear Axle Lubricant XY-8OW90-QL or equivalent meeting Ford specification WSP-M2C197-A until fluid level is within 6-14 mm (0.250-0.562 inch) below bottom of fill hole with the axle in operating position. Add 118 ml (4 ounces) of Additive Friction Modifier C8AZ-1913546-A or equivalent meeting Ford specification EST-M2C118-A for Traction-Lok axles. Install oil filler plug. Tighten to 20-41 Nm (15-30 ft. lbs.).
13. Make sure rear axle housing vent is not plugged with debris.