Pinion Seal

Removal & Installation

To Remove:

CAUTION
The rear face of the drive pinion nut has a color, which is critical to this procedure. Use the same color new drive pinion nut for installation unless you are installing a new collapsible spacer. Failure to do this can cause damage to the component.

1. Put the vehicle in NEUTRAL then raise and safely support the vehicle.

   NOTE: The rear wheels and brake drums need to be removed to prevent brake drag during the drive pinion bearing preload adjustment.

2. Remove the wheel and tire.
3. Remove the rear brake drums.
4. Put alignment marks on the driveshaft flange and pinion flange to ensure correct alignment at installation.
5. Remove the driveshaft flange-to-pinion-flange bolts.

   CAUTION
   The driveshaft centering socket yoke fits tightly on the rear axle pinion flange pilot. Do not hammer on the driveshaft or its components to disconnect the yoke from the flange. Pry only in the area shown below with an appropriate tool to disconnect the yoke from the flange or the component may be damaged.

6. Using an appropriate tool, disconnect the driveshaft centering socket yoke from the rear axle pinion flange.

   Pry only in the area shown to disconnect the yoke from the flange

7. Install an in-lb (Nm) torque wrench on the pinion nut and make note of the torque required to maintain rotation of the pinion through many revolutions.
8. Use the drive pinion flange holding fixture (205-126) to hold the pinion flange then remove and throw away the pinion nut.
9. Put alignment marks on the pinion flange and drive pinion stem to ensure correct alignment during installation.
10. Use the 2-jaw puller (205-D072) to remove the pinion flange.
11. Push up on the metal flange of the rear axle drive pinion seal then use gripping pliers and hit with a hammer until the rear axle pinion seal comes off.

To Install:

1. Lubricate the new rear axle drive pinion seal.
2. Use the drive pinion oil seal installer (205-208) to install the rear axle drive pinion seal.
3. Lubricate the splines on the pinion flange.
4. Use the marks made during removal to align the pinion flange and with the drive pinion shaft. If a new pinion flange is being installed, disregard the marks.
5. Use the drive pinion flange installer (205-002) to install the pinion flange.

   CAUTION
   Make sure to install a new pinion nut with the same color as the original if you are not replacing the collapsible spacer. If a new collapsible spacer is being installed then install the nut in the kit or the component can be damaged.

6. Place the new pinion nut.

   CAUTION
   Take note of the drive pinion nut information below:

   Part #389546-S100 (color: orange) for axles built before 7/16/07

   Part # 4320 (color: purple) for axles built after 7/16/07

   Part #4C121 (color: purple) kit with spacer for appropriate size axle

   CAUTION
   The pinion nut must NEVER be backed off to reduce preload. If it is necessary to reduce preload, a new collapsible spacer and pinion nut kit must be installed or the component might be damaged.

   NOTE: Make sure to remove the drive pinion flange holding fixture (205-126) while taking preload readings with the in-lb (Nm) torque wrench.

7. Use the drive pinion flange holding fixture (205-126) to hold the pinion flange and tighten the pinion nut.
8. Align the marks on the rear driveshaft and pinion flange.

   NOTE: The driveshaft centering socket yoke fits tightly on the rear axle pinion flange pilot. Tighten bolts in a crisscross pattern to ensure the yoke sits squarely on the flange.

9. Install the bolts. Torque to 83 ft-lb (112 Nm).
10. Install the rear brake drums.
11. Install the wheel and tire.