For 1990-2009 cars

### Flange Removal Procedure

#### Tool 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 from the rear axle. Refer to Two-Piece Propeller Shaft Replacement .
3. Remove the propeller shaft coupling from the rear axle.
4. The flange run-out is minimized and the pinion bearing preload is maintained by reassembling in the original position. Lightly center punch the alignment marks (1) on 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.

### Seal Removal Procedure

1. Remove the drive pinion flange if not previously removed.

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.

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

### Seal Installation Procedure

#### Tool Required

J 42108 Pinion Seal Driver

1. Lubricate the new seal with rear axle lubricant.
2. Lightly coat the outside of the replacement 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 rear axle housing until the tool bottoms on the differential housing.

### Flange Installation Procedure

#### Tool 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 recommended rear axle lubricant.
3. Seal the surface of the pinion flange with rear axle lubricant.
4. Install the differential drive pinion flange onto the differential drive pinion gear.
5. Install the differential drive pinion flange nut.

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.

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

6. 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.
7. 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 N·m to 1.7 N·m (9 lb in to 15 lb in) on the new bearings or 0.9 N·m to 1.2 N·m (8 lb in to 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 the preload is checked.

• | Carefully perform the final tightening only after the preload has been checked.

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

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

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

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