Front

Special Tools:

Removal
1. Raise and support the vehicle.

2. CAUTION: Index-mark the driveshaft to the flange to maintain driveline balance.

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

3. Measure and record the pinion bearing torque preload.
^ Rotate the pinion, using an Nm (inch lbs.) torque wrench. Record the torque necessary to maintain rotation of the pinion through several revolutions.

4. Install the Flange Holder. Remove and discard the pinion nut and washer.

5. Note: Index-mark the flange to the pinion shaft.

Remove the flange, using the Companion Flange Remover.

6. Remove the pinion seal, using the Puller and the Impact Slide Hammer. Discard the seal.
7. Clean and inspect the following:
^ The seal mounting surface.
^ The flange lugs and the flange end that contacts the bearing cone.
^ Make sure the flange nut counterbore and the seal contact surfaces are smooth and free of nicks.

Installation

1. Install the pinion seal, using the appropriate Pinion Seat Replacer.
^ Lightly coat the pinion seal lip with SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A.

2. CAUTION: Never use a metal hammer on the pinion flange or install the flange with power tools. If necessary, use a plastic hammer to tap on a tight fitting flange.

Note: Align the index marks made during removal.

Lightly coat the flange splines and seal mating area with SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A, and install the flange with a new washer and nut.

3. CAUTION: Never back off the pinion nut to reduce preload. If preload reduction is necessary, install a new collapsible spacer and pinion nut.

Tighten the pinion nut.
^ Install the Flange Holder to hold the flange while tightening the pinion nut.
^ Take frequent pinion bearing torque preload readings.
^ The final reading must be 0.56 Nm (5 inch lbs.) more than the initial reading taken during removal.

4. Align the index marks, and connect the driveshaft.
5. Check and, if necessary, fill the axle with the specified lubricant.