Section 05-03B: Axle, Front Drive, Dana Model 60 Monobeam
1996 F-350 4x4 Workshop Manual
REMOVAL AND INSTALLATION

Drive Pinion Oil 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 Seal ReplacerT56T-4676-B

Removal

  1. NOTE: The pinion seal can be replaced without removing the axle from the vehicle. Compounded or synthetic rubber seals do not require soaking.

    Raise the vehicle on a hoist or raise the front 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 axle to drop into the rebound position for working clearance.

  1. Mark U-joint flange and driveshaft prior to removing. Remove the nuts and two U-bolts from the front axle U-joint flange and disconnect the driveshaft from the front axle pinion flange. Wire the driveshaft to the frame.

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

  1. Using Companion Flange Remover Tool T65L-4851-B remove the companion flange.

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

Installation

  1. Clean the seat of the pinion seal. Drive the pinion seal into the housing using Pinion Seal Replacer T56T-4676-A. Coat the seal lip of the new seal with a small amount of Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A. Do not put sealer on the sealing lip.

  1. Coat the inside of the pinion flange with a small quantity of Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A and install the flange on the pinion shaft using Companion Flange Replacer TOOL-4858-E or equivalent.

  1. Install a new pinion attaching nut on the pinion shaft. Tighten to 298-379 Nm (220-280 lb-ft).

  1. Connect the driveshaft to the front axle pinion flange and align marks made prior to removal. Secure with nuts and U-bolts and tighten. Refer to Section 05-01.

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