Lincoln Navigator: Front Drive Axle/Differential / Drive Pinion Flange and Seal. Removal and Installation

Special Tool(s) / General Equipment

	205-002 (TOOL-4858-E) Installer, Drive Pinion Flange
	205-126 (T78P-4851-A) Holding Fixture, Drive Pinion Flange
	205-208 (T83T-4676-A) Installer, Drive Pinion Oil Seal TKIT-1983-F TKIT-1983-FLM TKIT-1983-FX
	303-144 (T79T-6316-A) Remover, Crankshaft Harmonic Balancer
Flat Headed Screw Driver

Materials

Removal

1. Remove the front brake pads.
   Refer to: Brake Pads (206-03 Front Disc Brake, Removal and Installation).
   

1. Remove the front driveshaft.
   Refer to: Front Driveshaft (205-01 Driveshaft, Removal and Installation).
   

1. NOTE: Rotational torque of the drive pinion flange must be measured and recorded using a Nm (lb-in) torque wrench for correct pinion bearing preload when reassembled. This will be the torque-to-turn measurement.

   1. Using a dial type torque wrench, measure and record the rotational torque of the drive pinion.
      
   2. Index-mark the pinion flange and the drive pinion stem.
      

1. Using the special tool, remove and discard the pinion nut.
   Use Special Service Tool: 205-126 (T78P-4851-A)  Holding Fixture, Drive Pinion Flange.

1. Using the special tool, remove the pinion flange.
   Use Special Service Tool: 303-144 (T79T-6316-A)  Remover, Crankshaft Harmonic Balancer.

1. Using the general equipment, remove and discard the drive pinion seal.
   Use the General Equipment: Flat Headed Screw Driver

1. Clean and inspect the pinion flange mating surfaces and pinion seal surface.
   

Installation

1. Using the special tool, install the new pinion seal.
   Use Special Service Tool: 205-208 (T83T-4676-A)  Installer, Drive Pinion Oil Seal.

1. Lubricate the pinion seal and pinion splines.
   Material: Motorcraft® SAE 75W-85 Premium Synthetic Hypoid Gear Lubricant / XY-75W85-QL (WSS-M2C942-A)

1. NOTE: Make sure drive pinion flange and drive pinion stem are phased correctly using previously applied mark.

   1. Align the index marks made during removal.
      
   2. Using the special tool, install the pinion flange.
      Use Special Service Tool: 205-002 (TOOL-4858-E)  Installer, Drive Pinion Flange.

1. NOTICE: Do not loosen the pinion nut to reduce drive pinion bearing preload. Install a new drive pinion collapsible spacer and pinion nut if drive pinion bearing preload reduction is necessary. If a new collapsible spacer must be installed for pinion bearing preload reduction, install the nut supplied with the new spacer or damage to the component may occur.

   NOTE: Tighten the pinion nut, rotating the pinion occasionally to make sure the drive pinion bearings are seating correctly. Take frequent drive pinion bearing preload readings by rotating the drive pinion gear with a Nm (lb-in) torque wrench. The final reading must be 0.56 Nm (5 lb-in) more than the initial reading taken during removal.

   NOTE: When installing the drive pinion flange and pinion nut with no differential carrier installed, the drag torque (torque to turn) should be 1.8 to 3.3 Nm (16-29 in-lbs).

   Using the special tool, install the new pinion nut.
   Use Special Service Tool: 205-126 (T78P-4851-A)  Holding Fixture, Drive Pinion Flange.

1. Check the front differential fluid level.
   Refer to: Differential Fluid Level Check (205-03 Front Drive Axle/Differential, General Procedures).
   

1. Install the front driveshaft.
   Refer to: Front Driveshaft (205-01 Driveshaft, Removal and Installation).
   

1. Install the front brake pads.
   Refer to: Brake Pads (206-03 Front Disc Brake, Removal and Installation).