Lincoln Nautilus: Rear Drive Axle/Differential / Drive Pinion Flange. Removal and Installation

Special Tool(s) / General Equipment

	205-126 (T78P-4851-A) Holding Fixture, Drive Pinion Flange
	205-495 Installer, Transmission Output Shaft Flange
Transmission Jack
Flat-Bladed Screwdriver
Two Leg Puller
Wooden Block

Materials

Removal

All vehicles

1. Remove the muffler and tail pipe.
   Refer to: Muffler and Tailpipe (309-00B Exhaust System - 2.7L EcoBoost (238kW/324PS), Removal and Installation).
   Refer to: Muffler and Tailpipe (309-00B Exhaust System - 2.7L EcoBoost (238kW/324PS), Removal and Installation).
   

1. 1. Index mark the driveshaft and the RDU flange for reference during installation.
      
   2. Remove and discard the driveshaft to RDU pinion flange bolts and retaining straps.
      

   3. NOTE: Do not remove driveshaft from the pinion flange by pulling on the driveshaft tube. Damage to the CV joint can result.

      NOTE: The driveshaft to drive pinion flange is a tight fit and will not come apart until the center bearing is lowered.

      Using a general equipment, separate the driveshaft from the drive pinion flange.
      Use the General Equipment: Flat-Bladed Screwdriver

2.0L

1. Remove the retainers and the center bearing heat shield.
   

1. NOTE: Do not allow the driveshaft to hang. Secure the driveshaft so the CV does not over articulate.

   
   Separate the driveshaft from the drive pinion flange.
   
   1. Remove and discard the rear center bearing bolts.
      
   2. Position the rear driveshaft aside.
      

Vehicle equipped with 2.7L EcoBoost Engine

1. NOTE: Do not allow the driveshaft to hang. Secure the driveshaft so the CV does not over articulate.

   
   Separate the driveshaft from the drive pinion flange.
   
   1. Remove and discard the rear center bearing bolts.
      
   2. Position the driveshaft aside.
      

All vehicles

1. Position a transmission jack and wooden block to secure the RDU .
   Use the General Equipment: Transmission Jack
   Use the General Equipment: Wooden Block

1. NOTE: Rotational torque of the drive pinion flange must be measured and recorded using a Nm (lb-in) torque wrench for correct pinion bearing preload when reassembled. This will be the torque-to-turn measurement.

   Using a dial type torque wrench, measure and record the rotational torque of the drive pinion.
   

1. Remove the front RDU mounting bolts and nuts.
   

1. Using the special tool to hold the pinion flange, remove and discard the RDU pinion nut.
   Install Special Service Tool: 205-126 (T78P-4851-A)  Holding Fixture, Drive Pinion Flange.

1. Index-mark the drive pinion flange and the drive pinion stem for reassembly.
   

1. Using a general equipment, remove the drive pinion flange.
   Use the General Equipment: Two Leg Puller

Installation

All vehicles

1. If necessary.
   Install a new drive pinion seal.
   Refer to: Drive Pinion Seal (205-02 Rear Drive Axle/Differential, Removal and Installation).
   

1. Lubricate the drive pinion flange mating surfaces with grease.
   Material: Motorcraft® Premium Long-Life Grease / XG-1-E1 (ESA-M1C75-B)

1. NOTE: Make sure drive pinion flange and drive pinion stem are phased correctly using previously applied mark.

   Align the index-mark and using the special tool, install the drive pinion flange.
   Use Special Service Tool: 205-495  Installer, Transmission Output Shaft Flange.

1. NOTICE: Under no circumstances is the pinion nut to be backed off to reduce drive pinion bearing preload. If reduced drive pinion bearing preload is required, a new drive pinion collapsible spacer and pinion nut must be installed or damage to the component may occur.

   NOTE: Refer to the rotational torque previously recorded with the Nm (lb-in) torque wrench. Tighten the pinion nut in small increments until it is within 0.3 Nm (3 lb-in) of the reference measurement. If 0.3 Nm (3 lb-in) is exceeded, then the collapsible spacer will be damaged and a new rear drive axle will be required.

   Using the special tool, install the RDU pinion nut.
   Install Special Service Tool: 205-126 (T78P-4851-A)  Holding Fixture, Drive Pinion Flange.

1. NOTE: Ensure that the subframe bushing anti-rotation tabs are engaged inside the slots on the RDU mounting bracket.

   Check the position of the RDU and subframe bushing anti-rotation tabs as shown.
   

1. Install the front RDU mounting bolts and nuts.
   Torque: 76 lb.ft (103 Nm)

1. Remove a transmission jack and wooden block from the RDU .
   Use the General Equipment: Transmission Jack
   Use the General Equipment: Wooden Block

Vehicle equipped with 2.7L EcoBoost Engine

1. 
   Install the driveshaft to the drive pinion flange.
   

   1. NOTE: Align the index-marks when installing the CV flange into the drive pinion flange.

      Position the driveshaft CV flange into the drive pinion flange.
      
   2. Install the new rear center bearing bolts.
      Torque: 22 lb.ft (30 Nm)

2.0L

1. 
   Install the driveshaft to the drive pinion flange.
   
   1. Position the driveshaft CV flange into the drive pinion flange.
      
   2. Install the new rear center bearing bolts.
      Torque: 41 lb.ft (55 Nm)

1. Install the center bearing heat shield and the retainers.
   Torque: 106 lb.in (12 Nm)

All vehicles

1. 1. NOTE: Make sure that the component is installed to the position noted before removal.

      Align the index-mark on the driveshaft to the rear axle pinion flange.
      
   2. Install the new driveshaft-to-pinion flange bolts and retaining straps.
      Torque: 26 lb.ft (35 Nm)

1. Install the muffler and tail pipe.
   Refer to: Muffler and Tailpipe (309-00B Exhaust System - 2.7L EcoBoost (238kW/324PS), Removal and Installation).
   Refer to: Muffler and Tailpipe (309-00B Exhaust System - 2.7L EcoBoost (238kW/324PS), Removal and Installation).
   

1. Check the RDU fluid level.
   Refer to: Differential Fluid Level Check (205-02 Rear Drive Axle/Differential, General Procedures).