Removal & Installation
Mark drive shaft in relation to companion flange, and remove drive shaft-to-companion flange retaining bolts. Slide drive shaft forward and rest on drive shaft hoop. To install, align marks and install bolts. Tighten bolts to 70-95 ft. lbs (95-129 N.m).
Removal
- Raise vehicle on a frame contact hoist and support pinion nose with a screw-type jack. Remove rear axle mount-to-axle cover retaining bolts. Install a mount bolt in the lower mount, allowing axle to pivot forward.
- Disconnect drive shaft. Remove front axle-mount-retaining nuts and slowly lower axle for access to companion flange. Support axle with jack stand.
- Using INCH lb. torque wrench, measure and record torque required to rotate pinion through several revolutions. This is the pinion bearing preload. Mark companion flange in relation to pinion stem for companion flange reinstallation. If installing a new companion flange, flange does not need to be marked. NOTE: Pinion oil seal replacement involves removal and installation of only pinion nut and companion flange. This operation disturbs pinion bearing preload. Carefully reset preload during assembling.
- With a suitable wrench and Companion Flange Holder (T78P-4851-A), remove pinion nut and companion flange. Wedge a screwdriver blade between pinion seal flange and differential housing. Pry seal flange clear of housing. Install a pair of locking pliers to seal flange. Carefully tap on locking pliers until seal is removed. DO NOT damage housing.
Installation
- Clean new pinion seal surface and install on Pinion Seal Replacer (T79P-4676-A). Install pinion seal in housing. Lubricate oil seal lips with Lubricant (C1AZS-19590-BA or ESA-M1C75-B). CAUTION: If seal becomes cocked or damaged in any way during installation, remove and replace with a new seal.
- Inspect pinion stem and companion flange for nicks and burrs. Deburr and smooth any rough surface. To complete installation, reverse removal procedures. Coat washer side of new pinion nut with gear lubricant and install nut. CAUTION: The companion flange must NEVER be hammered, or assembled with power tools.
- Check pinion bearing preload several times when tightening pinion nut until original preload is obtained. Fill differential with Rear Axle Lubricant (EOAZ-19580-AA) to bottom of oil filler hole. CAUTION: On models with Traction-Lok differential, add 3 ozs. (.09L) of Friction Modifier (C8AZ-19B546-A) to fluid.
Remove axle shafts. See DRIVE AXLE - REAR article. Using Pilot Bearing/Seal Remover (T77F-1102A), remove bearing and seal.
Note. If replacing only the oil seal, install pilot bearing and seal remover in bore and position bearing so tangs on pilot bearing/seal installer firmly engage on oil seal.
- Lubricate new pilot bearing with Rear Axle Lubricant (EOAZ-19580-A) and install using Differential Pilot Bearing Replacer (T89P-1244-A) and Driver Handle (D81L-4000-A).
- Lubricate lip of oil seal with Lubricant (C1AZ-19590-BA or ESA-M1C75-B). Install oil seal with Pilot Bearing Seal Replacer (T89P-4850-A) and Driver Handle (D81L-4000-A).
| CAUTION | Installation of bearing or oil seal assembly without proper components may result in early bearing or seal failure. If seal becomes cocked in the bore during installation, remove it and install a new one. |
- Remove axle shafts. See «DRIVE AXLE - REAR»(ref-46563) article. Install Differential Plugs (T89P-4850-B) in differential. Disconnect drive shaft.
- Support rear axle with transmission jack. Remove rear axle mount. Remove front retaining bolts, nuts, bushings and washers. Lower axle assembly from vehicle.
To install, reverse removal procedure. Fill differential with Rear Axle Lubricant (EOAZ-19580-AA) to bottom of oil filler hole.
| CAUTION | On models with Traction-Lok differential, add 3 ounces of Friction Modifier (C8AZ-19B546-A) to fluid level if axle has been drained. |
| CAUTION | Output shaft seals for axle shafts must be replaced when axle shaft is removed from differential. Install new circlips on axle shafts before installing. |
