Section 05-02D: Axle, Rear, Dana
1996 F-Super Duty Workshop Manual
REMOVAL AND INSTALLATION

Drive Pinion Seal

SPECIAL SERVICE TOOL(S) REQUIRED
DescriptionTool Number
Companion Flange Holding ToolT57T-4851-B
Companion Flange RemoverT65L-4851-B
Impact Slide HammerT50T-100-A
Pinion Oil Seal ReplacerT88T-4676-A
Companion Flange ReplacerT88T-4851-B

Removal

The rear axle drive pinion seal (4676) can be replaced without removing the rear axle assembly (4006) from the vehicle.

  1. Raise the vehicle on a hoist or raise the rear end of the vehicle with a jack. Install safety stands under the frame rails and lower the jack or hoist far enough to allow the rear axle (4001) to drop into the rebound position for working clearance.

  1. NOTE: Note and mark driveshaft/rear axle universal joint flange position so that it can be reassembled in the same position to minimize driveline vibration.

    Remove the straps and bolts which are threaded into the rear axle universal joint flange (4851). Wire the driveshaft (4602) to the frame.





  1. NOTE: The pinion nut requires 597-677 Nm (440-500 lb-ft) of torque to remove.

    Using Companion Flange Holding Tool T57T-4851-B to hold the companion flange, remove the differential pinion shaft nut.





  1. Using Companion Flange Remover T65L-4851-B or 2-Jaw Puller D80L-1002-L or equivalent, remove the rear axle universal joint flange.





  1. Using Seal Remover TOOL-1175-AC or equivalent in combination with Impact Slide Hammer T50T-100-A, remove the rear axle drive pinion seal.

Installation

  1.  CAUTION: Installation without the proper tool may result in early seal failure. If pinion seal becomes cocked during installation, remove and install new one. Use care to assure the garter spring remains in place during assembly. If the spring is dislodged, the rear axle drive pinion seal must be replaced.

    Clean the rear axle drive pinion seal seat. Coat the sealing edge of the new rear axle drive pinion seal with a small amount of hypoid gear lubricant or equivalent meeting Ford specification WSP-M2C197-A. Drive the rear axle drive pinion seal into the housing using Pinion Seal Replacer T88T-4676-A.





  1. NOTE: The rear axle universal joint flange must never be hammered on or installed with power tools.

    Coat the inside of the rear axle universal joint flange with a small quantity of hypoid gear lubricant or equivalent meeting Ford specification WSP-M2C197-A and install the rear axle universal joint flange on the drive pinion shaft using Companion Flange Replacer T88T-4851-B.





  1. Install the pinion attaching nut on the pinion stem and tighten to 597-677 Nm (440-500 lb-ft). Hold the rear axle universal joint flange with Companion Flange Holding Tool T57T-4851-B while tightening the nut.





  1. Connect the driveshaft to the rear axle universal joint flange as originally positioned. Secure with straps and bolts and tighten to Specifications listed at the end of this section.





  1. Raise the vehicle, remove the safety stands and lower the vehicle to road position. Check the level of axle lubricant and add the specified lubricant as necessary.