Rear Drive Axle/Differential - Dana 80

Drive Pinion Flange and Drive Pinion Seal


















Removal

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Vehicle Jacking and Lifting.

2. To maintain driveline balance, index-mark the driveshaft flange and the pinion flange.





3. Remove and discard the 4 driveshaft flange bolts.





4. NOTICE: The driveshaft flange fits tightly on the rear axle flange pilot. Using a suitable tool, pry only in the area shown to disconnect the driveshaft flange or damage to the driveshaft may occur.

NOTE: It may be necessary to tap the driveshaft flange with a plastic or rubber soft-faced hammer if a pry area is not available on the driveshaft flange.

NOTE: Do not allow the driveshaft to hang unsupported.

Using a suitable tool as shown, disconnect the driveshaft flange from the pinion flange and support the driveshaft using mechanic's wire.





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

Using the Drive Pinion Flange Holding Fixture to prevent the flange from turning, remove and discard the pinion shaft locknut and washer.





6. Using the 2 Jaw Puller, remove the pinion flange.





7. Using the Slide Hammer and Bushing Remover, remove the pinion seal.





8. Clean the rear axle pinion seal seat.

Installation

1. NOTICE: If the pinion seal becomes cocked during installation, remove the seal and install a new one. Make sure the garter spring remains in place during assembly. If the spring is dislodged, a new pinion seal must be installed or damage to the component may occur.

Using the Drive Pinion Oil Seal Installer, install the pinion seal.

- Coat the pinion seal (rubber lips) with lubricant.





2. NOTICE: The pinion flange must never be hammered on or installed with power tools or damage to the component may occur.

NOTE: Align the pinion-to-flange index marks.

Using the Drive Pinion Flange Installer, install the pinion flange.





3. NOTE: Always install a new washer and locknut.

Using the Drive Pinion Flange Holding Fixture to hold the pinion flange, install the new washer and locknut.

- Tighten to 637 Nm (470 lb-ft).





4. NOTE: Align the driveshaft flange-to-rear axle pinion flange index marks.

Position the driveshaft flange on the pinion flange and install 4 new bolts.

- Tighten to 100 Nm (74 lb-ft).