Ford F89Z-4676-AA Seal Assembly - Oil

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If the vehicle is equipped with air suspension, turn off the air suspension system. The switch is located in the area of the right kick panel. Loosen the rear wheel lug nuts, raise the rear of the vehicle and support it securely on jackstands. Block the front wheels to keep the vehicle from rolling off the stands. Remove the wheels, this will allow you to obtain a more accurate pinion shaft preload reading. Disconnect the driveshaft and fasten it out of the way. Use an inch-pound torque wrench to check the torque required to rotate the pinion. Record it for use later. Put alignment marks on the pinion shaft, nut and flange. Count the number of threads visible between the end of the nut and the end of the pinion shaft and record it for use later. A special tool can be used to keep the companion flange from moving while the self-locking pinion nut is loosened. If the special tool isn't available, insert a screwdriver through one of the bolt holes. Remove the pinion nut. Remove the companion flange. It may be necessary to use a two or three-jaw puller to pull off the flange. Do NOT attempt to pry behind the flange or hammer on the end of the pinion shaft. Pry out the old seal and discard it. Lubricate the lips of the new seal with high-temperature grease and tap it evenly into position with a seal installation tool or a large socket. Make sure it enters the housing squarely and is tapped in to its full depth. Align the mating marks made before disassembly and install the companion flange. If necessary, tighten the pinion nut to draw the flange into place. Do not try to hammer the flange into position. Apply non-hardening sealant to the ends of the splines visible in the center of the flange so oil will be sealed in. Install the washer (if equipped) and pinion nut. Tighten the nut carefully until the original number of threads are exposed. Measure the torque required to rotate the pinion and tighten the nut in small increments until it matches the figure recorded earlier. In order to compensate for the drag of the new oil seal, the nut should be tightened more until the rotational torque of the pinion slightly exceeds what was recorded earlier, but not by more than 5 in-lbs. Connect the driveshaft, install the wheels and lower the vehicle. Tighten the lug nuts.

Install the companion flange, aligning it with the marks made during removal. Gently tap the flange on with a soft-faced hammer until you can start the pinion nut on the pinion shaft.

Remove the half shaft assembly. Insert seal puller into the differential half shaft bore so the tangs on the tool firmly grab the inside of the oil seal. If this tool is not available, a large prybar can be used to pry the seals out. Connect a slide hammer to the seal puller and remove the seal. Installation: Lubricate the lip of the seal with multi-purpose grease. Carefully align the seal with the housing bore. Using the proper driver or a socket, extension and a hammer, install the oil seal. Drive the seal squarely into place. Caution: If the seal becomes cocked in the bore during installation, remove it and install a new one. Install the half shaft assembly.

Loosen the rear wheel lug nuts, raise the rear of the vehicle and place it securely on jackstands. Remove the rear wheels. Remove the brake drums or calipers. Mark the driveshaft and companion flange for ease of realignment during reassembly, then remove the driveshaft. Mark the relationship between the pinion and companion flange. Using an inch-pound torque wrench, measure and record the torque required to turn the pinion nut through several revolutions (pinion bearing preload). Using a suitable tool, hold the companion flange and remove the pinion nut. Using a suitable puller, remove the companion flange. Pry out the old seal with a slide hammer and reversed jaws or other appropriate tool. Clean the oil seal mounting surface. Tap the new seal into place, taking care to insert it squarely. Inspect the splines on the pinion shaft for burrs and nicks. Remove any rough areas with a crocus cloth. Wipe the splines clean. Install the companion flange, aligning it with the marks made during removal. Gently tap the flange on with a soft-faced hammer until you can start the pinion nut on the pinion shaft. Using a suitable tool, hold the companion flange while tightening the pinion nut to the minimum torque. While tightening, take frequent rotational torque measurements, using the inch-pound torque wrench, until the measurement recorded is reached. Caution: If the measurement was less than the pinion bearing preload torque, continue tightening until the specified preload is reached. If it was more than specified, stop when the specified preload is reached. Under no circumstances should the pinion nut be backed off to reduce pinion bearing preload. Increase the nut torque in small increments and check the preload after each increase. Reinstall the driveshaft, brake drums and wheels. Check the differential oil level and fill as necessary. Lower the vehicle and take a test drive to check for leaks.

Reinstall all components removed previously by reversing the removal process, tightening all fasteners to their specified torque values.

To remove the rear axle cover, first, raise the vehicle and support it with jack stands. Place a screw-type jack stand or a floor jack under the pinion nose. Remove the bolts and nuts securing the rear axle cover to the axle mount. Install the bolt for the rear mount in the lower bolt hole, allowing the axle to pivot forward. Reference mark the driveshaft to the companion flange and then remove the driveshaft-to-companion flange bolts. Slide the driveshaft forward, resting it on the driveshaft hoop. Remove the nuts retaining the carrier to the front mount. Lower the carrier slowly to gain access to the companion flange. Measure the torque required to turn the pinion using an inch-pound torque wrench and socket on the pinion nut, noting the measurement for later use. Reference mark the companion flange to the pinion shaft. Use a holding tool or equivalent and a breaker bar and socket to remove the pinion nut. If the tool is unavailable, install bolts into adjacent holes in the companion flange and brace a prybar to prevent pinion movement. Remove the companion flange. To remove the pinion seal, wedge a screwdriver blade between the metal flange of the seal and the housing, then pry up on the metal flange and use locking pliers to extract the seal by hitting the pliers with a hammer. For installation, use a seal installer or a pipe with an outside diameter slightly smaller than the seal, driving it squarely into place without cocking it in the housing. Inspect mating surfaces for burrs, remove any with emery cloth, and install the companion flange on the pinion shaft using reference marks. Install a new companion flange retaining nut, tightening it in increments and rotating the companion flange frequently to seat the bearing. Ensure the same turning torque for pinion preload without exceeding the recorded removal value. Note that exceeding the specified preload requires installing a new collapsible spacer and pinion nut, a task best handled by a professional service department or repair shop due to the specialized tools needed. The pinion nut must not be backed off to achieve proper preload.

Loosen the rear wheel lug nuts, raise the rear of the vehicle and place it securely on jackstands. Remove the rear wheels. Remove the brake drums or calipers. Mark the driveshaft and companion flange for ease of realignment during reassembly, then remove the driveshaft. Mark the relationship between the pinion and companion flange. Using an inch-pound torque wrench, measure and record the torque required to turn the pinion nut through several revolutions (pinion bearing preload). Using a suitable tool, hold the companion flange and remove the pinion nut. Using a suitable puller, remove the companion flange. Pry out the old seal with a slide hammer and reversed jaws or other appropriate tool. Clean the oil seal mounting surface. Tap the new seal into place, taking care to insert it squarely. Inspect the splines on the pinion shaft for burrs and nicks. Remove any rough areas with a crocus cloth. Wipe the splines clean. Install the companion flange, aligning it with the marks made during removal. Gently tap the flange on with a soft-faced hammer until you can start the pinion nut on the pinion shaft. Using a suitable tool, hold the companion flange while tightening the pinion nut to the minimum torque. While tightening, take frequent rotational torque measurements, using the inch-pound torque wrench, until the measurement recorded is reached. Caution: If the measurement was less than the pinion bearing preload torque, continue tightening until the specified preload is reached. If it was more than specified, stop when the specified preload is reached. Under no circumstances should the pinion nut be backed off to reduce pinion bearing preload. Increase the nut torque in small increments and check the preload after each increase. Reinstall the driveshaft, brake drums and wheels. Check the differential oil level and fill as necessary. Lower the vehicle and take a test drive to check for leaks.

To remove the rear axle cover, first, raise the vehicle and support it with jack stands. Place a screw-type jack stand or a floor jack under the pinion nose. Remove the bolts and nuts securing the rear axle cover to the axle mount. Install the bolt for the rear mount in the lower bolt hole, allowing the axle to pivot forward. Reference mark the driveshaft to the companion flange and then remove the driveshaft-to-companion flange bolts. Slide the driveshaft forward, resting it on the driveshaft hoop. Remove the nuts retaining the carrier to the front mount. Lower the carrier slowly to gain access to the companion flange. Measure the torque required to turn the pinion using an inch-pound torque wrench and socket on the pinion nut, noting the measurement for later use. Reference mark the companion flange to the pinion shaft. Use a holding tool or equivalent and a breaker bar and socket to remove the pinion nut. If the tool is unavailable, install bolts into adjacent holes in the companion flange and brace a prybar to prevent pinion movement. Remove the companion flange. To remove the pinion seal, wedge a screwdriver blade between the metal flange of the seal and the housing, then pry up on the metal flange and use locking pliers to extract the seal by hitting the pliers with a hammer. For installation, use a seal installer or a pipe with an outside diameter slightly smaller than the seal, driving it squarely into place without cocking it in the housing. Inspect mating surfaces for burrs, remove any with emery cloth, and install the companion flange on the pinion shaft using reference marks. Install a new companion flange retaining nut, tightening it in increments and rotating the companion flange frequently to seat the bearing. Ensure the same turning torque for pinion preload without exceeding the recorded removal value. Note that exceeding the specified preload requires installing a new collapsible spacer and pinion nut, a task best handled by a professional service department or repair shop due to the specialized tools needed. The pinion nut must not be backed off to achieve proper preload.

Remove the half shaft assembly. Insert seal puller into the differential half shaft bore so the tangs on the tool firmly grab the inside of the oil seal. If this tool is not available, a large prybar can be used to pry the seals out. Connect a slide hammer to the seal puller and remove the seal. Installation: Lubricate the lip of the seal with multi-purpose grease. Carefully align the seal with the housing bore. Using the proper driver or a socket, extension and a hammer, install the oil seal. Drive the seal squarely into place. Caution: If the seal becomes cocked in the bore during installation, remove it and install a new one. Install the half shaft assembly.

Clean the oil seal mounting surface thoroughly. Tap the new seal into place, ensuring it is inserted squarely.

Loosen the rear wheel lug nuts, raise the rear of the vehicle and place it securely on jackstands. Remove the rear wheels. Remove the brake drums or calipers. Mark the driveshaft and companion flange for ease of realignment during reassembly, then remove the driveshaft. Mark the relationship between the pinion and companion flange. Using an inch-pound torque wrench, measure and record the torque required to turn the pinion nut through several revolutions (pinion bearing preload). Using a suitable tool, hold the companion flange and remove the pinion nut. Using a suitable puller, remove the companion flange. Pry out the old seal with a slide hammer and reversed jaws or other appropriate tool. Clean the oil seal mounting surface. Tap the new seal into place, taking care to insert it squarely. Inspect the splines on the pinion shaft for burrs and nicks. Remove any rough areas with a crocus cloth. Wipe the splines clean. Install the companion flange, aligning it with the marks made during removal. Gently tap the flange on with a soft-faced hammer until you can start the pinion nut on the pinion shaft. Using a suitable tool, hold the companion flange while tightening the pinion nut to the minimum torque. While tightening, take frequent rotational torque measurements, using the inch-pound torque wrench, until the measurement recorded is reached. Caution: If the measurement was less than the pinion bearing preload torque, continue tightening until the specified preload is reached. If it was more than specified, stop when the specified preload is reached. Under no circumstances should the pinion nut be backed off to reduce pinion bearing preload. Increase the nut torque in small increments and check the preload after each increase. Reinstall the driveshaft, brake drums and wheels. Check the differential oil level and fill as necessary. Lower the vehicle and take a test drive to check for leaks.