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Most rear axle leakage conditions can be corrected without a teardown. However, it is important to clean up the leaking area enough to identify the exact source.
A plugged rear axle housing vent (4022) can cause wheel or pinion seal leaks due to internal pressure buildup.
Make sure axle lubricant level is 6.4-14.2mm (1/4-9/16 inch) for Ford axles or 6.4-19.1mm (1/4-3/4 inch) for Dana axles below bottom of fill hole.
****** Yoke Seal
When the rear axle drive pinion seal (4676) leaks, it is usually because it was not installed carefully or properly, or because of poor quality on the seal journal surface.
Any damage to the seal bore (dings, dents, gouges or other imperfections) will distort the seal casing and allow leakage past the outer edge of the rear axle drive pinion seal.
The rear axle drive pinion seal can be torn, cut or gouged if it is not assembled carefully. The spring that holds the rear axle drive pinion seal against the rear axle universal joint ****** (4851) may be knocked out, allowing leakage past the lip.
The rubber lip can harden (like plastic) with cracks at the oil lip contact point, especially in presence of high temperatures. The contact point on the rear axle universal joint ****** is usually black, indicating excessive heat. Marks, nicks, gouges or rough surface texture on the seal journal of the rear axle universal joint ****** will also cause leaks. Excessive rear axle drive pinion seal wear will be noted. The rear axle universal joint ****** should be replaced if any of these conditions exist.
Metal chips or sand trapped at the sealing lip also may cause oil leaks. This can cause a wear groove on the rear axle universal joint ****** and heavy pinion seal wear.
When any seal leaks, confirm that air passes freely through vent hose and fitting. Clean out as needed.
There have been instances of oil leaking past the threads of the pinion nut. The condition can be corrected by removing the nut and applying Pipe Sealant With Teflon® D8AZ-19554-A or equivalent meeting Ford specification WSK-M2G350-A2 on the threads and nut face.
9.75 Inch Ring Gear
1.Before servicing the vehicle, refer to the precautions section.
NOTE
If equipped, turn the air suspension switch to the OFF position.
NOTE
The rear wheels and brake calipers must be removed to prevent brake drag during drive pinion bearing preload adjustment.
2.With the vehicle in NEUTRAL, position the vehicle on a hoist.
3.Remove the rear wheel and tire assemblies.
4.Remove the rear brake calipers and the brake discs.
5.Remove the rear driveshaft assembly.
6.Install a Nm (lb-in) torque wrench on the nut and record the torque necessary to maintain rotation of the drive pinion gear through several revolutions
WARNING
After removing the pinion nut, discard it. Use a new nut for installation.
7.Use the special tool to hold the pinion ****** while removing the pinion nut.
8.Index-mark the drive pinion ****** and the drive pinion gear stem to maintain initial balance during installation.
9.Using the special tool 205-D072, remove the drive pinion ******.
http://content.chiltonsonline.com/content/images/22086/images/22086_expd_g0082.pdfPinion ****** removal with jaw puller
Pinion ****** removal with jaw puller
10.Force up on the metal ****** of the drive pinion seal. Install gripping pliers and strike with a hammer until the pinion seal is removed.
To install:
1.Lubricate the lips of the new drive pinion seal with grease.
2.Using the special tool 205-208, install the drive pinion seal.
3.Lubricate the drive pinion ****** splines with rear axle lubricant
4.Position the drive pinion ******.
5.Using the special tool 205-233, install the drive pinion ******.
http://content.chiltonsonline.com/content/images/22086/images/22086_expd_g0083.pdf
Drive pinion ****** installation with special tool
Click to Enlarge
6.Position the new drive pinion nut
WARNING
Do not under any circumstance loosen the nut to reduce preload. If it is necessary to reduce preload, install a new drive pinion collapsible spacer and nut.
7.Use the special tool 205-126 to hold the pinion ****** while tightening the nut.
Rotate the pinion occasionally to make sure the pinion bearings seat correctly. Take frequent pinion bearing torque preload readings by rotating the drive pinion gear with a Nm (lb-in) torque wrench
If the preload recorded prior to disassembly is lower than the specification for used bearings, tighten the nut to 16-29 inch. lbs. (1.8-3.3 mm).
If the preload recorded prior to disassembly is higher than the specification for used bearings, tighten the nut to the original reading as recorded.
NOTE
Install the driveshaft with new bolts. If new bolts are not available, apply sealer to the threads of the original bolts.
8.Align the index marks.
NOTE
The driveshaft ****** yoke fits tightly on the pinion ****** pilot. To make sure that the yoke seats squarely on the ******, tighten the bolts evenly in a cross pattern as shown.
9.Install the rear driveshaft.
10.Install the rear brake discs and the brake calipers.
11.Check fluid level and add if needed.
12.Install the rear wheel and tire assemblies.
13.Lower the vehicle.
14.If equipped with air suspension, reactivate the system.
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Ford 10.5 Inch Ring Gear Axle
NOTE
The rear wheels and brake calipers must be removed to prevent brake drag during drive pinion bearing preload adjustment.
1.Remove the rear brake calipers.
2.Remove the driveshaft.
3.Install a Nm torque wrench on the pinion nut and record the rotational torque required to maintain rotation of the pinion through several revolutions.
CAUTION
After removal of the pinion nut, discard it. A new nut must be used for installation.
4.Using the too 205-126l, hold the pinion ****** while removing the pinion nut.
5.Mark the pinion ****** in relation to the drive pinion stem to make sure alignment is correct during installation.
6.Using puller tool 205-D072, remove the pinion ******.
7.Force up on the metal ****** of the rear axle drive pinion seal. Install gripping pliers to the seal ****** and strike with a hammer until the rear axle drive pinion seal is removed.
To install:
1.Lubricate the new pinion seal with clean premium long-life grease.
CAUTION
If the rear axle drive pinion seal becomes misaligned during installation, remove the rear axle drive pinion seal and replace it with a new seal.
2.Using seal installer tool 205-208, install a new rear axle drive pinion seal.
3.Lubricate the pinion ****** splines with clean synthetic rear axle lubricant.
NOTE
Disregard the scribe marks if a new pinion ****** is being installed.
4.Align the pinion ****** with the drive pinion shaft.
5.With the pinion ****** in place in the rear axle housing, use tool 205-233 to install the pinion ******.
6.Position the new pinion nut.
CAUTION
Under no circumstances is the pinion nut to be backed off to reduce preload. If reduced preload is required, a new collapsible spacer and pinion nut must be installed.
7.Use holding tool 205-126 to hold the pinion ****** while tightening the pinion nut.
8.Tighten the pinion nut, rotating the pinion occasionally to make sure the cone and roller bearings are seating correctly. Take frequent cone and roller bearing torque preload readings until the original recorded preload reading is obtained by rotating the pinion with a Nm torque wrench.
9.Install the driveshaft.
10.Install the brake calipers.
