Dana 30 Front Drive Axle/Differential

Drive Pinion Flange and Seal











Removal

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

1. With the vehicle in NEUTRAL, position it on a hoist.

2. NOTE: The front wheels and tires and brake calipers must be removed to prevent drag during the pinion bearing preload recording and adjustment.

Remove the front tires and wheels.

3. Remove the front driveshaft.

4. CAUTION: When removing the disc brake caliper, never allow it to hang from the brake hose or damage to the component may occur.

Remove the 4 disc brake caliper anchor bolts, then remove the disc brake calipers and disc brake caliper anchors as an assembly.
^ Using mechanic's wire, position and support the disc brake calipers and disc brake caliper anchors.





5. Measure and record the pinion bearing preload.
^ Using a Nm torque wrench, rotate the pinion gear. Measure the torque required to maintain pinion gear rotation.





6. Index-mark the pinion flange and the pinion gear stem.





7. Using the special tool to hold the pinion flange, remove and discard the pinion nut.





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





9. Inspect the pinion flange for burrs and damage. Inspect the end of the pinion flange that contacts the pinion bearing cone, pinion nut counterbore and drive pinion oil seal surface for nicks. Discard the pinion flange if damaged.

10. Using gripping pliers and a hammer, remove the drive pinion oil seal.





11. Remove the drive pinion oil slinger and the outer pinion bearing.





12. Remove and discard the collapsible spacer.
13. Verify the splines on the pinion stem are free of burrs. If burrs are evident, remove them with a fine crocus cloth.
14. Clean the drive pinion oil seal bore.

Installation
1. Install a new collapsible spacer.
2. Install the outer pinion bearing and the drive pinion oil slinger.





3. NOTE: Lubricate the drive pinion oil seal lips with axle lubricant.

Using the special tool, install the drive pinion oil seal.





4. CAUTION: Never install the pinion flange with power tools or damage to the component may occur.

Align the index marks and using the special tool, install the pinion flange.





5. Install the new pinion nut. Only hand-tighten the pinion nut at this time.





6. CAUTION: Do not loosen the pinion nut to reduce pinion bearing preload. Install a new collapsible spacer and pinion nut if pinion bearing preload reduction is necessary or damage to the component may occur.

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





7. Install the disc brake calipers and disc brake caliper anchors as an assembly, then the 4 disc brake caliper anchor bolts.
^ Tighten to 108 Nm (80 lb-ft).





8. CAUTION: Always connect the front driveshaft to the axle first. Otherwise, the weight of the driveshaft may pinch the boot between the shaft and the flange and cause the boot to tear.

NOTE: Install the driveshaft with new bolts and washers and new bolts and U-joint retainers. If new bolts are not available, coat the threads of the original bolts with Threadlock(R) and sealer.

Install the front driveshaft.
9. Install the front tires and wheels.