Dana

Special Tools:

Removal
1. Raise the vehicle on a hoist or raise the rear end of the vehicle with a jack. Install safety stands under the frame rails and lower the jack or hoist enough to allow the rear axle to drop into the rebound position for working clearance.

2. CAUTION: Index-mark the driveshaft components to maintain driveline balance during assembly.

Disconnect the driveshaft at the axle, and position it aside.

3. CAUTION: Index-mark the pinion flange to the pinion shaft prior to removal.

Use the special tool to prevent the flange from turning while removing the lock nut and washer.

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

5. Using the special tools, remove and discard the pinion seal.
6. Clean the pinion seal seat.

Installation
1. Lubricate the pinion seal rubber lips.
- Use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A

2. Using the special tool, install the pinion seal.
- For Model 60/70 axles, use tool 205-208.
- For Model 80 axles, use tool 205-284.
- After installation, verify that the garter spring did not pop out of the seal. If the garter spring popped out, install a new pinion seal.

3. Coat the inside of the pinion flange with a small amount of lubricant.
- Use SAE 80W-90 Premium Rear Axle Lubricant XY-8OW90-QL or equivalent meeting Ford specification WSP-M2C197-A

4. Install the pinion flange.
- For Model 80 axles, use the special tool.

5. CAUTION: Always install a new washer and lock nut.

Use the special tool to prevent the flange from turning while installing the new washer and lock nut.
- For Model 60/70 axles, tighten the nut to 339 Nm (250 ft. lbs.).
- For Model 80 axles, tighten the nut to 637 Nm (470 ft. lbs.).

6. CAUTION: Align the index marks made during removal.

Connect the driveshaft to the axle.

7. Check, and as necessary, fill the axle with the specified type and amount of lubricant.
8. Lower the vehicle.