Front Drive Axle/Differential - Dana 35

Drive Pinion Seal

Special Tools:

Special Tool(s)

Removal

CAUTION: This operation disturbs the differential pinion bearing preload. Carefully reset the preload during assembly.

1. Raise and support the vehicle.

2. CAUTION:
^ Index-mark the front axle pinion flange and the front driveshaft, and the front output shaft and the front driveshaft constant velocity joint.
^ Always disconnect the front driveshaft from the transfer case first. Otherwise, the weight of the driveshaft can pinch the boot between the shaft and the boot can and cause the boot to tear.
^ Tape the bearing cups to prevent them from falling off the spider.
^ Remove the front driveshaft.





3. Measure the pinion bearing preload.
^ Using a Nm (inch-pound) torque wrench, measure the torque necessary to maintain pinion rotation. Record the measurement.





4. Index-mark the pinion flange and the pinion stem.





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

6. CAUTION: Place a drain pan under the differential housing.





Using the special tool, remove the pinion flange.
7. Inspect the pinion flange for burrs and damage. Inspect the end of the pinion flange that contacts the bearing cone, the nut counterbore, and the seal surface for nicks. Discard the pinion flange as necessary.





8. Using the special tool and a suitable slide hammer, remove the pinion seal.





9. Remove the front axle drive pinion shaft oil slinger and the differential pinion bearing.
10. Remove and discard the collapsible spacer.

Installation

1. Verify that the splines on the pinion stem are free of burrs. If bum are evident, remove them with a fine crocus cloth. Work in a rotating motion to wipe the pinion clean.
2. Clean the pinion seal bore.
3. Install a new collapsible spacer.





4. Install the original differential pinion bearing and the front axle drive pinion shaft oil slinger.
5. Lubricate the pinion seal.





6. Using the special tool, install the pinion seal.
7. Lubricate the pinion flange splines.

8. 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.





Align the index marks and install the pinion flange.





9. Install the new nut hand-tight.

10. CAUTION: Do not loosen the nut to reduce preload. Install a new collapsible spacer and nut if preload reduction is necessary.

NOTE: Remove the special tool before taking the differential pinion bearing preload reading.





Use the special tool to hold the pinion flange while tightening the nut to set the preload.
^ Tighten the nut, rotating the pinion occasionally to make sure the differential pinion bearings are seating correctly. Take frequent differential pinion bearing preload readings by rotating the pinion with a NM (inch-pound) torque wrench. The final reading must be 0.56 Nm (5 inch lbs.) more than the initial reading taken during removal.

11. CAUTION:
^ Align the index marks.
^ Always connect the front driveshaft to the axle first. Otherwise, the weight of the driveshaft can pinch the boot between the shaft and the boot can and cause the boot to tear.
^ Install the driveshaft with new bolts and washers and new bolts and universal joint retainers. If new bolts are not available, coat the threads of the original bolts with Threadlock.

Install the front driveshaft.
12. Check and, if necessary, fill the axle with lubricant to 9.56 mm (0.38 inch) below the bottom of the axle fill hole.
13. Lower the vehicle.