Tools Required

J 42066 Wheel Bearing Hub Flange Holding Tool

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the propeller shaft. Refer to Two-Piece Propeller Shaft Replacement .
3. Remove the propeller shaft coupling.



4. The flange run-out is minimized and the pinion bearing preload is maintained by reassembling in the original position. Lightly match-mark (1) the following as an aid for reassembly:

•	On the differential drive pinion flange nut (3).

•	On the differential drive pinion flange (4).

•	On the differential drive pinion gear end (2).

5. Install the J 42066 onto the differential drive pinion flange.
6. Use the J 42066 to hold the differential drive pinion flange.
7. Remove the differential drive pinion flange nut.
8. Remove the J 42066 .
9. Install a universal gear puller to the pinion flange.
10. Remove the pinion flange from the differential drive pinion gear.

1. Remove the drive pinion flange.



2. Use a drift (1) and use a deadblow hammer to remove the differential drive pinion oil seal (2) from the differential housing.

Important: Position the drift on an angle to drive the seal inward away from the housing surface to prevent affecting the surface condition of the housing. Take care not to damage the differential housing as this could result in a leak after reassembly.

Tools Required

J 42108 Pinion Seal Driver

1. Lubricate the lip of the new seal with rear axle lubricant.
2. Lightly coat the outside of the new seal with a non-hardening gasket cement.
3. Use the J 42108 to drive the seal (1) over the pinion gear (2) squarely into the differential housing.

Tools Required

J 42066 Wheel Bearing Hub Flange Holding Tool

1. Ensure that the drive pinion gear shaft threads are free from burrs.
2. Coat the splines with the rear axle lubricant.
3. Coat the surface of the pinion flange with rear axle lubricant.
4. Install the differential drive pinion flange onto the differential drive pinion gear.

Important: The pinion flange has an interference fit on the pinion gear shaft splines. The pinion flange should only be pulled into place by tightening the retaining nut. Do NOT use force or hammer the flange during the installation of the drive pinion flange onto the drive pinion.

Install the differential drive pinion flange nut.

Tighten
Gradually tighten the flange nut until the pinion shaft end play is reduced to approximately 0.50 mm (0.020 in).




5. If REUSING the drive pinion flange continue tightening the nut while alternatively turning the pinion gear to seat the bearings until the alignment marks (1) align. Then, further tighten the nut no more than an additional 5 degrees. Backing off the pinion flange nut to compensate for overtightening the nut will not properly set preload.



6. If a NEW drive pinion flange is installed, the differential must be removed to set the drive pinion bearing preload. Set the preload without the carrier installed and with the bearings lubricated to 1.0-1.7 N·m (9-15 lb in) on the new bearings or 0.9-1.2 N·m (8-11 lb in) with used bearings.

•	The preload specifications are being approached when no further end play is detectable and when the holder will no longer pivot freely as the differential drive pinion gear is rotated.

•	Do NOT attempt further tightening until you have tested the preload.

•	Carefully perform the final tightening only after you have tested the preload.

•	Minute tightening of the nut adds significant pound inches of turning torque.

•	Further tighten the nut slightly while testing the preload after each tightening.

•	Exceeding the preload specifications compresses the collapsible spacer too far, thus requiring the installation of a new spacer.

7. Install the propeller shaft coupling.
8. Install the propeller shaft. Refer to Two-Piece Propeller Shaft Replacement .
9. Fill and inspect the lubricant level. Refer to Lubricant Level Check .
10. Lower the vehicle.