For 1990-2009 cars

### Removal Procedure

#### Tools Required

J 8614-01 Pinion Flange Remover and Installer

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the propeller shaft. Refer to One-Piece Propeller Shaft Replacement or Two-Piece Propeller Shaft Replacement in Propeller Shaft.
3. Mark the position of the following components before disassembly:

• | The drive pinion gear yoke (1)

• | The drive pinion gear

• | The drive pinion gear nut

• | This action will ensure that the correct drive pinion gear inner and outer bearing preload can be maintained.

4. Use J 8614-01 in order to remove the following components:

• | The drive pinion gear nut

• | The drive pinion gear washer

5. Use a suitable container in order to hold any fluid that may drain from the rear axle.
6. Use J 8614-01 in order to remove the drive pinion gear yoke (1).

Important: Do not damage the rear axle housing when removing the drive pinion gear seal.

7. Use a blunt chisel in order to drive the drive pinion gear seal (1) out of the rear axle housing.
8. Inspect the drive pinion gear seal (1) surface of the drive pinion gear yoke for the following conditions:

• | Tool marks

• | Nicks

• | Damage, such as a groove worn by the drive pinion gear seal.

9. If the drive pinion gear yoke is damaged, replace the drive pinion gear yoke.
10. Inspect the housing bore for burrs.

Burrs might cause leaks around the outer diameter (OD) of the drive pinion gear seal (1).

Remove any burrs that might cause leaks around the outer diameter (OD) of the drive pinion gear seal (1).

### Installation Procedure

#### Tools Required

• | J 8614-01 Pinion Flange Remover and Installer

• | J 23911 Pinion Oil Seal Installer

1. Use the J 23911 in order to install a new drive pinion gear seal (1).
2. Apply chassis lubricant or an equivalent to the following components:

• | The outside diameter of the drive pinion gear yoke

• | The sealing lip of the new drive pinion gear seal (1)

3. Install the drive pinion gear yoke (1).
4. Install the following components:

• | The drive pinion gear washer

• | The drive pinion gear nut

• | Finger tighten the drive pinion gear nut.

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.

5. Hold the drive pinion gear yoke. Use J 8614-01 in order to tighten the drive pinion gear nut to the position that was marked.

Tighten
Tighten the drive pinion gear nut to 1.59 mm (1/16 inch) beyond the alignment mark.

6. Install the propeller shaft. Refer to One-Piece Propeller Shaft Replacement or Two-Piece Propeller Shaft Replacement in Propeller Shaft.
7. Measure the rear axle lubricant level and add lubricant, if necessary. Refer to Lubricant Level Check .
8. Lower the vehicle.
9. Inspect for correct operation of the rear axle.