Pinion Flange: Service and Repair

Special Tools:

Removal

1. CAUTION: Do not allow the calipers to hang from the brake hoses.

NOTE: Remove the rear wheels and the brake calipers to prevent drag during the drive pinion bearing preload adjustment.

Remove and secure the rear brake calipers aside.





2. CAUTION: Index-mark the driveshaft flange and pinion flange to maintain initial balance during installation.

Disconnect and position the driveshaft out of the way.





3. Install an Nm (inch/pound) torque wrench on the pinion nut and record the torque necessary to maintain rotation of the drive pinion gear through several revolutions.





4. CAUTION: After removing the pinion nut, discard it. Use a new nut for installation.

Use the special tool to hold the pinion flange while removing the pinion nut.





5. Mark the pinion flange in relation to the drive pinion stem to ensure correct alignment during installation.





6. Using the special tool, remove the pinion flange.

Installation
1. Lubricate the pinion flange splines.
^ Use Thermally Stable Rear Axle Lubricant XY-SOW90-QL or equivalent meeting Ford specification WSP-M2CI97-A.





2. NOTE: Disregard the alignment marks if installing a new pinion flange.

Align the pinion flange with the drive pinion shaft.





3. Using the special tools, install the pinion flange.





4. CAUTION: Do 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 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 Nm (inch/pound) torque wrench.
^ If the preload recorded prior to disassembly is lower than the specification for used bearings, then tighten the pinion nut to specification. If the preload recorded prior to disassembly is higher than the specification for used bearings, then tighten the pinion nut to the original reading as recorded.
^ Refer to the torque specification for used pinion bearings in the Specifications.





5. CAUTION: Be sure to align the index-marks.

Connect the driveshaft
6. Install the rear brake calipers.
7. Install the rear wheel and tire assemblies.