Pinion Flange: Service and Repair

Drive Pinion Flange/Yoke and/or Oil Seal Replacement

Special Tools
* J 21128 - Axle Pinion Oil Seal Installer
* J 38694 - Extension Housing Pump/Seal Installer
* J 45012 - Holding Fixture
* J 45019 - Flange and Pinion Cage Remover

For equivalent regional tools, refer to Special Tools (Tools and Equipment).

Removal Procedure

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
2. Remove the propeller shaft assembly. Refer to Two-Piece Propeller Shaft Replacement (Two-Piece Propeller Shaft Replacement).





Note: Record this measurement for reassembly.

3. Using an inch-pound torque wrench, measure the rotational torque of the differential ring and pinion gear and related components.




4. Using the J 45012 - fixture, remove and discard the pinion nut (1).
5. Using the J 45019 - remover, remove the drive pinion flange (2).




6. Using the appropriate tool, remove the drive pinion seal (1).

Installation Procedure




1. Position the drive pinion seal (1) in the differential housing.




2. Using the appropriate tool (1), install the drive pinion seal (2) in the rear axle housing (3).

* For the 195 mm rear differential, use the J 21128 - installer.
* For the 218 mm rear differential, use the J 38694 - installer.




3. Position the drive pinion flange (2) on the drive pinion shaft.

Note: Install the drive pinion flange on the drive pinon shaft so that there 3 to 4 threads showing.

4. Using a brass hammer, tap the drive flange (2) on the drive pinion shaft.
5. Using the J 45019 - remover, install the drive flange.
6. Hand start the NEW drive pinon nut (1).

Note: Rotate the pinion while tightening the pinion nut to seat the bearings.

7. Using the J 45012 - fixture, tighten the drive pinion flange nut until the pinion end play is just taken up.
8. Using an inch-pound torque wrench and tightening in small increments, measure the rotating torque of the pinion until the reading is the same as the rotational torque noted at removal. If the rotational torque during removal could not be recorded, tighten the pinon nut in small increments until a rotating torque of 2.45-3.70 Nm (22-33 lb in) for the 195 mm rear differential or 3.18-4.7 Nm (28-42 lb in) for the 218 mm rear differential is achieved.
9. Using a hammer and a punch, stake two sides of the drive pinion nut to the grooves in the drive pinion gear.
10. Check the fluid level of the rear drive axle. Refer to Rear Axle Lubricant Level Inspection (Procedures).
11. Install the propeller shaft assembly. Refer to Two-Piece Propeller Shaft Replacement (Two-Piece Propeller Shaft Replacement)
12. Remove the support and lower the vehicle.