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IRS pinion flange installation
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<blockquote data-quote="THunterW" data-source="post: 13819830" data-attributes="member: 149912"><p>I just installed a new pinion flange in my IRS since I'm in the middle of rebuilding my entire IRS differential. I didn't have the expensive tool from Ford that actually installs the flange onto the pinion gear without having to install the nut. I set up my pinion gear and installed the flange into the gears grooves and used my pinion nut to suck the flange onto the gear itself. There was still plenty of play even with the flange fully installed since my crush sleeve hadn't compressed yet (I actually used the Ratech "smart sleeve" instead of the OEM crush sleeve supplied in my FRPP gear kit). Once I got the remaining forward to aft play taken up in the pinion, I torqued the pinion nut to 130 ft/lbs and gave it another 1/8 of a turn and had actually set my pinion preload right under the tightest limit, at 28 in/lbs. If you haven't removed the differential carrier from the case you might be able to hammer a new pinion flange onto your housing with a soft faced mallet or deadblow, since the pinion gear will be meshed against the ring gear, not allowing it to move on you. I would definitely remove the cover and inspect everything internally though since now would be the time to replace bearings and gears before you install the IRS case back onto the car.</p></blockquote><p></p>
[QUOTE="THunterW, post: 13819830, member: 149912"] I just installed a new pinion flange in my IRS since I'm in the middle of rebuilding my entire IRS differential. I didn't have the expensive tool from Ford that actually installs the flange onto the pinion gear without having to install the nut. I set up my pinion gear and installed the flange into the gears grooves and used my pinion nut to suck the flange onto the gear itself. There was still plenty of play even with the flange fully installed since my crush sleeve hadn't compressed yet (I actually used the Ratech "smart sleeve" instead of the OEM crush sleeve supplied in my FRPP gear kit). Once I got the remaining forward to aft play taken up in the pinion, I torqued the pinion nut to 130 ft/lbs and gave it another 1/8 of a turn and had actually set my pinion preload right under the tightest limit, at 28 in/lbs. If you haven't removed the differential carrier from the case you might be able to hammer a new pinion flange onto your housing with a soft faced mallet or deadblow, since the pinion gear will be meshed against the ring gear, not allowing it to move on you. I would definitely remove the cover and inspect everything internally though since now would be the time to replace bearings and gears before you install the IRS case back onto the car. [/QUOTE]
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