For 1990-2009 cars

#### Tools Required

• | J 42066 Hub Holding Tool

• | J 42108 Seal Installer

### Removal Procedure

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 in Propeller Shaft.
3. Remove the propeller shaft coupling.
4. Reference mark (1) the following components:

• | The differential drive pinion flange nut (3).

• | The differential drive pinion flange (4).

• | The differential drive pinion gear end (2).

5. Install the J 42066 onto the differential drive pinion flange.
6. Using the J 42066 to hold the differential drive pinion flange, remove the differential drive pinion flange nut.
7. Remove the J 42066 .
8. Using a universal gear puller, remove the pinion flange from the drive pinion gear shaft.

Important: Do not damage the differential housing when removing the pinion oil seal.

9. Use a drift (1) in order to remove the differential drive pinion oil seal (2) from the differential housing.

### Installation Procedure

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.
4. Ensure that the drive pinion gear shaft threads are free from burrs.
5. Coat the splines with the rear axle lubricant.
6. Coat the surface of the pinion flange with rear axle lubricant.

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.

7. Install the differential drive pinion flange onto the differential drive pinion gear.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

8. 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).

9. If REUSING the drive pinion flange continue tightening the nut while alternately turning the pinion gear in order to seat the bearings until the reference marks (1) align. 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.

Important: Exceeding the preload specifications will compress the collapsible spacer, requiring the installation of a new spacer. Do NOT attempt further tightening until the preload has been tested.

10. If a NEW drive pinion flange is installed, the differential carrier must be removed to set the drive pinion bearing preload. Set the preload, with the bearings lubricated, to:

Specification

• | 1.0-1.7 N·m (9-15 lb in) when installing new bearings.

• | 0.9-1.2 N·m (8-11 lb in) when reusing bearings.

11. Install the propeller shaft coupling.
12. Install the propeller shaft. Refer to Two-Piece Propeller Shaft Replacement in Propeller Shaft.
13. Inspect the lubricant level. Refer to Lubricant Level Check .
14. Lower the vehicle.