Rear 8.8 Inch Ring Gear

Special Tools:

REMOVAL
1. Remove the differential case.

2. Mark the driveshaft flange and the driveshaft rear axle companion flange for correct alignment during installation.

3. Remove the four rear driveshaft bolts and disconnect the rear driveshaft.

4. Install an Nm (inch-pound) torque wrench on the pinion nut and record the torque required to maintain rotation of the pinion through several revolutions.
5. Remove the rear axle companion flange and pinion nut.

6. Using a soft-faced hammer, drive the pinion assembly out of the front bearing cone and remove it through the rear of the housing.
^ Remove the rear axle drive pinion seal.
^ Remove the rear axle drive pinion shaft oil slinger.

7. Use the Bearing Pulling Attachment to remove the pinion bearing.

NOTE: Remove the collapsible spacer and discard it.

8. If the pinion bearing cups are to be replaced, tap alternately (with a brass drift of suitable length) on opposite sides of the cup during removal to prevent the cup from cocking in the casting.

NOTE: Do not remove the pinion bearing cups from the carrier casting unless the cups are damaged.

INSTALLATION

1. Drive the outer pinion bearing cup into the axle housing using the Pinion Bearing Cup Replacer and Driver Handle.

2. Drive the inner pinion bearing cup into the axle housing using the Pinion Bearing Cup Replacer and Driver Handle.

3. Make sure the cups are properly seated in their bores.

CAUTION: Whenever the cups are replaced, the pinion bearings must also be replaced.

NOTE: If a feeler gauge can be inserted between a cup and the bottom of its bore at any point around the cup, the cup is not properly seated.

4. Assemble and position the Pinion Depth Gauge.

NOTE: Apply only a light oil film on the pinion bearings before assembling the tool.

5. Tighten the Driver Handle to the specification shown.

6. Rotate the Gauge Block several half-turns to ensure proper seating of the pinion bearings and position the Gauge Block.

NOTE: The Gauge Block must be offset to obtain an accurate reading.

7. Install the Gauge Tube.
1 Position the Gauge Tube.
2 Install the differential side bearing caps.
3 Install the four differential side bearing cap bolts.

8. Use a drive pinion bearing adjustment shim as a gauge for shim selection.
^ After the proper shim thickness has been determined, remove the Gauge Tube.

NOTE: Drive pinion bearing adjustment shims must be flat and clean. A slight drag should be felt for correct shim selection. Do not attempt to force the pinion shim between the Gauge Block and the Gauge Tube. This will minimize selection of a pinion shim thicker than required, which results in a deep tooth contact in final assembly of integral rear axle assemblies.

9. Use a press and Pinion Bearing Cone Replacer to press the pinion bearing until it is firmly seated on the pinion and pinion shim.

10. Place a new collapsible spacer on the pinion shaft against the pinion stem shoulder.

11. From inside the rear axle housing, install the drive pinion assembly (drive pinion, shims, rear bearing cone and roller, and drive pinion collapsible spacer) into the rear axle carrier bore.

12. Install a new rear axle drive pinion seal.
1 Install the front pinion bearing cone and roller.
2 Install the rear axle drive pinion shaft oil slinger in the rear axle housing.
3 Install the rear axle drive pinion seal on the Pinion Seal Replacer.

CAUTION: Installation without the proper tool can result in early seal failure. If the rear axle drive pinion seal becomes cocked during installation, remove it and install a new one.

13. Place the Pinion Seal Replacer in the rear axle drive pinion seal bore, and drive the rear axle drive pinion seal into place.

NOTE: Coat the lips of the rear axle drive pinion seal with Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.

14. Lubricate the rear axle companion flange splines.
^ Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.

15. Align the rear axle companion flange with the drive pinion shaft.

NOTE: Disregard the scribe marks if a new rear axle companion flange is being installed.

16. With the drive pinion in place in the rear axle housing, install the rear axle companion flange using the Companion Flange Replacer.

17. Position the new pinion nut.

18. Use the Companion Flange Holding tool to hold the rear axle companion flange while tightening the pinion nut.

CAUTION: Under no circumstances is the pinion nut to be backed off to reduce preload. If reduced preload is required, a new collapsible spacer and pinion nut must be installed.

19. Install the differential case in the rear axle differential carrier.