Pinion Flange: Service and Repair

Drive Pinion Flange and Drive Pinion Seal

















Removal

NOTICE: This operation disturbs the pinion bearing preload. 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 pinion nut in the kit or damage to the component may occur.

1. NOTE: Remove the rear brake discs to prevent brake drag during drive pinion bearing preload adjustment.

NOTE: When removing the rear brake caliper in this procedure, it is not necessary to disconnect the hydraulic lines.

Remove the rear brake discs. For additional information, refer to Rear Disc Brake Brake Disc.

2. Remove the driveshaft. For additional information, refer to Driveshaft Removal and Replacement.

3. Install a Nm (lb-in) torque wrench on the nut and record the torque necessary to maintain rotation of the pinion through several revolutions.





4. Use the Drive Pinion Flange Holding Fixture to hold the pinion flange while removing the nut.





5. Index-mark the pinion flange and the drive pinion stem for correct alignment during installation.





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





7. 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. Coat the new rear axle drive pinion seal lips with grease.

2. NOTE: Installation without the correct tool can result in early seal failure.

NOTE: If the rear axle drive pinion seal becomes misaligned during installation, remove the seal and install a new seal.

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





3. Lubricate the pinion flange splines with rear axle lubricant.

4. NOTE: Disregard the index marks if installing a new pinion flange.

Align the pinion flange with the drive pinion shaft.





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





6. Install the new washer and pinion nut. Only hand-tighten the pinion nut at this time.

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

Using the Drive Pinion Flange Holding Fixture to hold the pinion flange, tighten the pinion nut to set the drive pinion bearing preload.

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

8. Install the driveshaft. For additional information, refer to Driveshaft Removal and Replacement.

9. Install the rear brake discs. For additional information, refer to Rear Disc Brake Brake Disc.