Front Drive Pinion Seal Removal on Ford Explorer?

Pinion Seal
REMOVAL & INSTALLATION procedure will work for

Lincoln Aviator, Ford Explorer, Exp Sport, Exp Sport-Trac, Mercury Mountaineer 2000-2005.

This instructions with details and diagrams is as follows :----

Removal & Installation

NOTE

This operation disturbs the differential pinion bearing preload. Carefully reset the preload during assembly.

CAUTION

The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations.

1. Before servicing the vehicle, please familiarize yourself with safety procedures.
2. Index-mark the front driveshaft and pinion flange.
3. Remove or disconnect the following:
   
   NOTE

   Do not allow the driveshaft to hang unsupported.
   
   
   
   
   Front driveshaft from the pinion flange, and position it aside
4. Using an Nm (inch-pound) torque wrench, measure the torque required to maintain pinion rotation. Record the measurement.
5. Index-mark the pinion flange and the pinion stem.
6. Hold the pinion flange while removing the nut.
7. Place a drain pan under the differential housing.
8. Using a puller, remove the pinion flange.
9. Inspect the pinion flange for burrs and damage. Inspect the end of the pinion flange that contacts the bearing cone, the nut counterbore, and the seal surface for nicks. Discard the pinion flange as necessary.
10. Using a seal remover and impact slide hammer, remove the pinion seal.
11. Remove the front axle drive pinion shaft oil slinger and the differential pinion bearing.
12. Remove and discard the collapsible spacer.

To install:

1. Verify that the splines on the pinion stem are free of burrs. If burrs are evident, remove them with a fine crocus cloth. Work in a rotating motion to wipe the pinion clean.
2. Clean the pinion seal bore.
3. Install a new collapsible spacer.
4. Install the original differential pinion bearing and the front axle drive pinion shaft oil slinger.
5. Lubricate the pinion seal. Use Motorcraft SAE 80W90 Thermally Stable 4x4 Axle Lubricant meeting Ford specification WSP-M2C197-A.
6. Install the pinion seal.
7. Lubricate the pinion flange splines. Use Motorcraft SAE 80W90 Thermally Stable 4x4 Axle Lubricant meeting Ford specification WSP-M2C197-A.
   
   NOTE

   Never use a metal hammer on the pinion flange or install the flange with power tools. If necessary, use a plastic hammer to tap on a tight fitting flange.
   
   
   
   NOTE

   Do not loosen the nut to reduce preload. Install a new collapsible spacer and nut if preload reduction is necessary.
   
   
   
   
   Align the index marks and install the pinion flange.

   Install the new nut hand-tight.
8. Use the special tool to hold the pinion flange while tightening the nut to set the preload.
9. Tighten the nut, rotating the pinion occasionally to ensure the differential pinion bearings are seating correctly. Take frequent differential pinion bearing preload readings by rotating the pinion with a Nm (inch-pound) torque wrench. The final reading must be 5 inch lbs. (0.56 Nm) more than the initial reading taken during removal.
10. Align the index marks and position the front driveshaft.
11. Install the universal joint spider retainers and bolts.
12. Check the fluid level and, if necessary, fill the axle to specification. Use Motorcraft SAE 80W90 Thermally Stable 4x4 Axle Lubricant meeting Ford specification WSP-M2C197-A.
13. Lower the vehicle.
14. If so equipped, reactivate the air suspension.

NOTE

This operation disturbs the differential pinion bearing preload. Carefully reset the preload during assembly.

CAUTION

The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Index-mark the front driveshaft and pinion flange.
3. Remove or disconnect the following:
   
   NOTE

   Do not allow the driveshaft to hang unsupported.
   
   
   
   
   Front driveshaft from the pinion flange, and position it aside
4. Using a Nm (inch-pound) torque wrench, measure the torque required to maintain pinion rotation. Record the measurement.
5. Index-mark the pinion flange and the pinion stem.
6. Hold the pinion flange while removing the nut.
7. Place a drain pan under the differential housing.
8. Using a puller, remove the pinion flange.
9. Inspect the pinion flange for burrs and damage. Inspect the end of the pinion flange that contacts the bearing cone, the nut counterbore, and the seal surface for nicks. Discard the pinion flange as necessary.
10. Using a seal remover and impact slide hammer, remove the pinion seal.
11. Remove the front axle drive pinion shaft oil slinger and the differential pinion bearing.
12. Remove and discard the collapsible spacer.

To install:

1. Verify that the splines on the pinion stem are free of burrs. If burrs are evident, remove them with a fine crocus cloth. Work in a rotating motion to wipe the pinion clean.
2. Clean the pinion seal bore.
3. Install a new collapsible spacer.
4. Install the original differential pinion bearing and the front axle drive pinion shaft oil slinger.
5. Lubricate the pinion seal. Use Motorcraft SAE 80W90 Thermally Stable 4x4 Axle Lubricant meeting Ford specification WSP-M2C197-A.
6. Install the pinion seal.
7. Lubricate the pinion flange splines. Use Motorcraft SAE 80W90 Thermally Stable 4x4 Axle Lubricant meeting Ford specification WSP-M2C197-A.
   
   NOTE

   Never use a metal hammer on the pinion flange or install the flange with power tools. If necessary, use a plastic hammer to tap on a tight fitting flange.
   
   
   
   NOTE

   Do not loosen the nut to reduce preload. Install a new collapsible spacer and nut if preload reduction is necessary.
   
   
   
   
   Align the index marks and install the pinion flange.

   Install the new nut hand-tight.
8. Use the special tool to hold the pinion flange while tightening the nut to set the preload.
9. Tighten the nut, rotating the pinion occasionally to ensure the differential pinion bearings are seating correctly. Take frequent differential pinion bearing preload readings by rotating the pinion with a Nm (inch-pound) torque wrench. The final reading must be 0.56 Nm (5 inch lbs.) more than the initial reading taken during removal.
10. Align the index marks and position the front driveshaft.
11. Install the universal joint spider retainers and bolts.
12. Check the fluid level and, if necessary, fill the axle to specification. Use Motorcraft SAE 80W90 Thermally Stable 4x4 Axle Lubricant meeting Ford specification WSP-M2C197-A.
13. Lower the vehicle.
14. If so equipped, reactivate the air suspension.

NOTE

This operation disturbs the differential pinion bearing preload. Carefully reset the preload during assembly.

1. Before servicing the vehicle, refer to the -Precautions- section.
2. With the vehicle in NEUTRAL, position it on a hoist.
   
   NOTE

   The front wheels and tires and brake calipers must be removed to prevent drag during the pinion bearing preload recording and adjustment.
3. Remove the front tires and wheels.
4. Remove the front driveshaft as follows:
   1. Index-mark the front driveshaft to maintain balance.
      
      
      

      

      Fig. Index-mark the front driveshaft to maintain balance
   2. Remove and discard the 6 CV joint bolts and CV joint washers.
   3. Remove the 4 universal joint strap bolts and remove the universal joint straps.
   4. Remove the front driveshaft.
5. Remove the disc brake caliper anchor bolts, then remove the disc brake caliper and disc brake caliper anchor as an assembly. Suspend on mechanic-s wire.
6. Measure and record the pinion bearing preload. Using a torque wrench, rotate the pinion gear. Measure the torque required to maintain pinion gear rotation.
   
   
   

   

   Fig. Measure and record the pinion bearing preload: using a torque wrench, rotate the pinion gear. Measure the torque required to maintain pinion gear rotation
7. Index-mark the pinion flange and the pinion stem.
   
   
   

   

   Fig. Index-mark the pinion flange and the pinion stem
8. Hold the pinion flange while removing the nut.
9. Place a drain pan under the differential housing.
10. Using a puller, remove the pinion flange.
11. Inspect the pinion flange for burrs and damage. Inspect the end of the pinion flange that contacts the bearing cone, the nut counterbore, and the seal surface for nicks. Discard the pinion flange as necessary.
12. Using a seal remover and impact slide hammer, remove the pinion seal.
13. Remove the front axle drive pinion shaft oil slinger and the outer pinion bearing.
14. Remove and discard the collapsible spacer.

To install:

1. Verify that the splines on the pinion stem are free of burrs. If burrs are evident, remove them with a fine crocus cloth. Work in a rotating motion to wipe the pinion clean.
2. Clean the pinion seal bore.
3. Install a new collapsible spacer.
4. Install the pinion bearing and the front axle drive pinion shaft oil slinger.
5. Lubricate the pinion seal with axle lubricant.
6. Install the pinion seal, using a proper seal installer to ensure the seal is fully and evenly seated.
7. Lubricate the pinion flange splines with axle lubricant.
   
   NOTE

   Never use a metal hammer on the pinion flange or install the flange with power tools. If necessary, use a plastic hammer to tap on a tight fitting flange.
   
   
   
   NOTE

   Do not loosen the pinion nut to reduce preload. Install a new collapsible spacer and nut if preload reduction is necessary.
   
   
   
   
   Align the index marks and install the pinion flange.

   Install the new nut hand-tight.
8. Use the special tool to hold the pinion flange while tightening the nut to set the preload.
9. Tighten the nut, rotating the pinion occasionally to ensure the differential pinion bearings are seating correctly. Take frequent differential pinion bearing preload readings by rotating the pinion with a Nm (inch-pound) torque wrench. The final reading must be 5 inch lbs. (0.56 Nm) more than the initial reading taken during removal.
10. Install the disc brake caliper and disc brake caliper anchor as an assembly, then the disc brake caliper anchor bolts to 80 ft. lbs. (108 Nm).
11. Install the front driveshaft as follows:
    1. Align the index marks and position the front driveshaft.
       
       CAUTION

       Always connect the front driveshaft to the axle first. Otherwise, the weight of the driveshaft can pinch the boot between the shaft and the flange and cause the boot to tear.
       
       
       
       CAUTION

       Install the driveshaft with new bolts and washers and new bolts and universal joint retainers. If new bolts are not available, coat the threads of the original bolts with threadlock and sealer.
    2. Install 4 new U-joint strap bolts and torque to 14 ft. lbs. (19 Nm).
    3. Install 6 new CV joint bolts and washers. Torque the bolts to 22 ft. lbs. (30 Nm).
12. Check and adjust the fluid level, if necessary.
13. Lower the vehicle.

This will help.

Thanks.

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Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html