Front

Special Tools:

Removal

WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations.

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

Note: The front drive axle must be in NEUTRAL before beginning this procedure

1. Raise and support the vehicle.





2. Remove the front differential support.
1 Remove the nut and bolt.
2 Remove the nuts and bolts.
3 Remove the front differential support.





3. Index-mark the front driveshaft to the axle universal joint flange.





4. CAUTION: Do not allow the driveshaft to hang unsupported.

Disconnect and support the front driveshaft.
1 Remove the four bolts.
2 Carefully disconnect and support the front driveshaft.





5. Using a Nm (inch/pound) torque wrench, measure the torque necessary to maintain pinion rotation. Record the measurement for reference during installation.





6. Index-mark the axle universal joint flange to the pinion stem.





7. Install the special tool, and loosen, but do not remove the pinion nut.





8. CAUTION: Before proceeding, place a drain pan under the differential carrier.

With the pinion nut still engaged by a few threads, use the special tool to separate the axle universal joint flange from the pinion gear.
9. Remove the nut and the flange.
10. Inspect the axle universal joint flange for burrs, the nut counterbore and the seal contact surface for nicks, and the bearing cone contact area for damage. Install a new flange if necessary.
11. Check the pinion stem splines for burrs. If burrs are evident, remove them with a fine crocus cloth. Working in a rotating motion, wipe the pinion clean.

Installation
1. Lubricate the axle universal joint flange splines and the pinion seal.
- Use Motorcraft SAE 75W-90 Premium 4x4 Front Axle Lubricant XY-75W90-TQL or equivalent meeting Ford specification WSP-M2C201-A.





2. CAUTION: Never install the axle universal joint flange with a hammer or power tools.

Note: Disregard the scribe marks if installing a new flange.

Align the index-marks and position the axle universal joint flange on the pinion shaft.





3. Note: Rotate the pinion gear occasionally to make sure the pinion bearings seat correctly.

Using the special tool, install the axle universal joint flange.








4. CAUTION: Do not loosen the pinion nut to reduce preload under any circumstance. If it is necessary to reduce preload, install a new drive pinion collapsible spacer and pinion nut.

Install the special tool, and tighten the pinion nut.
- Rotate the pinion gear occasionally to make sure the pinion bearings are seating correctly. Take frequent pinion bearing torque preload readings by rotating the pinion gear with a Nm (inch/pound) torque wrench.
- If the preload recorded prior to disassembly is lower than the specification for used bearings, then tighten the pinion nut to the specification. If the preload recorded prior to disassembly is higher than the specification for used bearings, then tighten the pinion nut to the original reading as recorded.





5. Align the index-marks then attach the front driveshaft.





6. Install the front differential support.
7. Inspect and, if necessary, fill the differential.
- Use Motorcraft SAE 75W-90 Premium 4x4 Front Axle Lubricant XY-75W9O-TQI or equivalent meeting Ford specification WSP-M2C201-A.
8. Lower the vehicle.
9. If equipped with air suspension, reactivate the system by turning on the air suspension switch.