Lincoln Corsair: Rear Drive Axle/Differential / Removal and Installation - Drive Pinion Flange

Special Tool(s) / General Equipment

	205-126 (T78P-4851-A) Holding Fixture, Drive Pinion Flange
	205-233 (T85T-4851-AH) Installer, Drive Pinion Flange TKIT-1985-FH-1
	303-249 Remover, Crankshaft Timing Pulley
Flat-Bladed Screwdriver

Materials

Removal

1. Remove the muffler and tail pipe.
   Refer to: Muffler and Tailpipe (309-00A Exhaust System - 2.0L EcoBoost (177kW/240PS) – MI4, Removal and Installation).
   Refer to: Muffler and Tailpipe (309-00B Exhaust System - 2.3L EcoBoost (199kW/270PS), Removal and Installation).
   

1. 1. Index mark the driveshaft and the RDU flange for reference during installation.
      
   2. Remove and discard the driveshaft to RDU pinion flange bolts and retaining straps.
      

   3. NOTE: Do not remove driveshaft from the pinion flange by pulling on the driveshaft tube. Damage to the CV joint can result.

      NOTE: The driveshaft to drive pinion flange is a tight fit and will not come apart until the center bearing is lowered.

      Using a general equipment, separate the driveshaft from the drive pinion flange.
      Use the General Equipment: Flat-Bladed Screwdriver
   4. Position aside and support the rear driveshaft.
      

1. NOTE: Do not allow the driveshaft to hang. Secure the driveshaft so the CV-joint does not over articulate.

   
   Separate the driveshaft from the drive pinion flange.
   
   1. Remove the rear center bearing nuts.
      
   2. Position the driveshaft aside.
      

1. Remove the bolts and the stabilizer bar.
   

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.

   Using a dial type torque wrench, measure and record the rotational torque of the drive pinion.
   

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

1. Index-mark the drive pinion flange and the drive pinion stem for reassembly.
   

1. Using a special tool, remove the drive pinion flange.
   Use Special Service Tool: 303-249  Remover, Crankshaft Timing Pulley.

Installation

1. If necessary.
   Install a new drive pinion seal.
   Refer to: Drive Pinion Seal (205-02 Rear Drive Axle/Differential, Removal and Installation).
   

1. Lubricate the drive pinion flange mating surfaces with grease.
   Material: Motorcraft® Premium Long-Life Grease / XG-1-E1 (ESA-M1C75-B)

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

   Align the index-mark and using the special tool, install the drive pinion flange.
   Use Special Service Tool: 205-233 (T85T-4851-AH)  Installer, Drive Pinion Flange.

1. NOTICE: Under no circumstances is the pinion nut to be backed off to reduce drive pinion bearing preload. If reduced drive pinion bearing preload is required, a new drive pinion collapsible spacer and pinion nut must be installed or damage to the component may occur.

   NOTE: Refer to the rotational torque previously recorded with the Nm (lb-in) torque wrench. Tighten the pinion nut in small increments until it is within 0.3 Nm (3 lb-in) of the reference measurement. If 0.3 Nm (3 lb-in) is exceeded, then the collapsible spacer will be damaged and a new rear drive axle will be required.

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

1. Install the stabilizer bar and the bolts.
   Torque: 35 lb.ft (48 Nm)

1. 
   Install the driveshaft to the drive pinion flange.
   
   1. Position the driveshaft CV flange into the drive pinion flange.
      
   2. Install the rear center bearing nuts.
      Torque: 41 lb.ft (55 Nm)

1. 1. NOTE: Make sure that the component is installed to the position noted before removal.

      Align the index-mark on the driveshaft to the RDU flange.
      
   2. Install the new driveshaft to RDU pinion flange bolts and retaining straps.
      Torque: 26 lb.ft (35 Nm)

1. Install the muffler and tail pipe.
   Refer to: Muffler and Tailpipe (309-00A Exhaust System - 2.0L EcoBoost (177kW/240PS) – MI4, Removal and Installation).
   Refer to: Muffler and Tailpipe (309-00B Exhaust System - 2.3L EcoBoost (199kW/270PS), Removal and Installation).
   

1. Check the RDU fluid level.
   Refer to: Differential Fluid Level Check (205-02 Rear Drive Axle/Differential, General Procedures).