Removal and Installation - Pinion Flange

Special Service Tools / General Equipment

	205-126 (T78P-4851-A) Holding Fixture, Pinion Flange
	205-233 (T85T-4851-AX) Installer, Pinion Flange TKIT-1985-FX-1
	303-249 Puller, Crankshaft Pulley
Transmission Jack
Flat-blade screwdriver
Wood block

Materials

Removal

1. 1
   Remove the muffler and exhaust pipe.
   Refer to: Muffler and Exhaust Pipe - 4WD (309-00A Exhaust System - 1.5 L EcoBoost (132 kW/180 L PS) - I3 (Y1), Removal and Installation).
   Refer to: Muffler and Exhaust Pipe (309-00B Exhaust System - 2 L EcoBoost (177 kW/240 L PS) - MI4, Removal and Installation).
   Refer to: Muffler and Exhaust Pipe - Plug-In Hybrid Electric Vehicle (PHEV) (309-00C Exhaust System, Removal and Installation).
2. 2
   1. Mark the driveshaft and the RDU flange with an index mark for reference during installation.

   2. Remove and discard the driveshaft flange-to-RDU pinion bolts and the retaining clamps.

   3. Using common shop equipment, separate the driveshaft from the pinion flange.
      Use common shop equipment: flat-blade screwdriver.

   4. Set the rear driveshaft aside and support it.

   

3. 3
   
   Separate the driveshaft from the drive pinion flange.
   

   1. Remove the rear center bearing nuts.

   2. Set the driveshaft aside.

   

4. 4
   Install the transmission jack and wooden block to support the RDU.
   Use common shop equipment: transmission jack.
   Use common shop equipment: wooden block

   

5. 5
   Using a torque wrench with a scale, measure and record the pinion torque.

   

6. 6
   Remove the RDU front mounting bolts and the RDU shield.

   

7. 7
   Holding the pinion flange with the special tool, remove and discard the pinion nut.
   Install special service tool: 205-126 (T78P-4851-A) Holding Fixture, Pinion Flange.

   

8. 8
   Mark the pinion flange and the pinion shaft for reassembly.

   

9. 9
   Using the special tool, remove the pinion flange.
   Use special service tool: 303-249 Puller, Crankshaft Pulley.

   

Installation

1. 1
   If necessary.
   Install a new pinion seal.
   Refer to: Pinion Seal (205-02 Rear Axle/Differential, Removal and Installation).
2. 2
   Lubricate the mating surfaces of the pinion flange with multi-purpose grease.
   Material: Motorcraft® Premium Long-Life Grease / XG-1-E1 (ECA-M1C75-B)

   

3. 3
   Align the index mark and, using the special tool, install the pinion flange.
   Use special service tool: 205-233 (T85T-4851-AX) Installer, Pinion Flange.

   

4. 4

   NOTICE: Under no circumstances should the pinion nut be loosened to reduce pinion bearing preload. If the pinion preload is reduced, a new collapsible pinion spacer and pinion nut must be installed, otherwise component damage may occur.

   Using the special tool, install the RDU pinion nut.
   Install special service tool: 205-126 (T78P-4851-A) Holding Fixture, Pinion Flange.

   

5. 5
   Install the RDU protective shield and front mounting bolts.
   Torque: 76 lb-ft (103 N·m)

   

6. 6
   Remove the transmission jack and wood block from the RDU.
   Use common equipment: transmission jack.
   Use common equipment: wood block

   

7. 7
   
   Install the driveshaft to the pinion flange.
   

   1. Position the CV driveshaft flange on the pinion flange.

   2. Install the rear center bearing nuts.
      Torque: 41 lb-ft (55 N·m)

   

8. 8
   1. Align the mark on the driveshaft with the RDU flange.

   2. Install the new driveshaft onto the RDU flange bolts and retaining clamps.
      Torque: 26 lb-ft (35 N·m)

   

9. 9
   Install the muffler and exhaust pipe.
   Refer to: Muffler and Exhaust Pipe — 4WD (309-00A Exhaust System — 1.5 L EcoBoost (132 kW/180 L hp) — I3 (Y1), Removal and Installation).
   Refer to: Muffler and Exhaust Pipe (309-00B Exhaust System — 2 L EcoBoost (177 kW/240 L hp) — MI4, Removal and Installation).
   Refer to: Muffler and Exhaust Pipe — Plug-In Hybrid Electric Vehicle (PHEV) (309-00C Exhaust System, Removal and Installation).
10. 10
    Check the RDU fluid level.
    Refer to: Differential Fluid Level Check (205-02 Rear Axle/Differential, General Procedures).