Rear Drive Axle/Differential - Ford 9.75-Inch Ring Gear

Drive Pinion Flange and Drive Pinion Seal

















Removal

NOTICE: The color on the rear face of the drive pinion nut is critical to this repair. Use the same color new drive pinion nut for installation. If a new collapsible spacer must be installed for pinion bearing preload reduction, install the nut supplied with the new spacer or damage to the component may occur.

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

2. Remove the brake disc. For additional information, refer to Rear Disc Brake Brake Disc.

3. Index-mark the driveshaft flange and pinion flange for correct alignment during installation.





4. Remove and discard the 4 driveshaft flange bolts.





5. NOTE: The driveshaft centering socket yoke fits tightly on the pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft centering socket yoke from the pinion flange. Pry only in the area shown with a suitable tool to disconnect the driveshaft centering socket yoke from the pinion flange.

Using a suitable tool as shown, disconnect the driveshaft centering socket yoke from the pinion flange.

- Using mechanic's wire, position the driveshaft aside.





6. Using a Nm (lb-in) torque wrench on the pinion nut, record the torque required to maintain rotation of the pinion gear through several revolutions.





7. Using the Drive Pinion Flange Holding Fixture to hold the pinion flange, remove and discard the pinion nut.





8. Index-mark the pinion flange in relation to the drive pinion stem to make sure of correct alignment during installation.





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





10. Force up on the metal flange of the drive pinion seal. Install gripping pliers and strike with a hammer until the drive pinion seal is removed.





Installation

1. Lubricate the new drive pinion seal with grease.

2. Using the Drive Pinion Oil Seal Installer, install a new drive pinion seal.





3. Lubricate the pinion flange splines with axle lubricant.

4. NOTE: Disregard the scribe marks if a new pinion flange is being installed.

Align the pinion flange with the drive pinion shaft.





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





6. NOTICE: Install a new pinion nut with the same color as the original if not replacing the collapsible spacer. If a new collapsible spacer is installed, install the nut in the kit, as indicated in the chart below, or damage to the component may occur.

Position the new pinion nut.

9.75 Inch Drive Pinion Nut









7. NOTICE: Under no circumstances is the pinion nut to be backed off to reduce drive pinion bearing preload. If reduced drive pinion bearing preload is required, a new drive pinion collapsible spacer and pinion nut must be installed or damage to the component may occur.

NOTE: Remove the Drive Pinion Flange Holding Fixture while taking drive pinion bearing preload readings with the Nm (lb-in) torque wrench.

Using the Drive Pinion Flange Holding Fixture to hold the pinion flange, tighten the pinion nut.

- Rotate the drive pinion occasionally to make sure the drive pinion bearings are seating correctly.

- Install a Nm (lb-in) torque wrench on the pinion nut.

- Rotating the drive pinion through several revolutions, take frequent drive pinion bearing preload readings until the original recorded drive pinion bearing preload reading is obtained.

- If the original recorded drive pinion bearing preload is lower than specification, tighten to the appropriate specification for used drive pinion bearings. If the drive pinion bearing preload is higher than specification, tighten the pinion nut to the original reading as recorded. For additional information, refer to the Specification.





8. Position the driveshaft and align the index mark on the pinion flange.





9. NOTE: The driveshaft centering socket yoke fits tightly on the pinion flange pilot. To make sure that the driveshaft centering socket yoke seats squarely on the pinion flange, tighten the driveshaft flange bolts evenly in a cross pattern.

Install the 4 new driveshaft flange bolts.

- Tighten to 103 Nm (76 lb-ft).





10. Install the rear brake disc. For additional information, refer to Rear Disc Brake Brake Disc.