Ford AU/BA/BF/EA/EB/ED Falcon 1988-2010 Factory Service & Shop Manual

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Complete workshop & service manual with electrical wiring diagrams for 1988-2010 Ford AU/BA/BF/EA/EB/ED Falcon & Fairlaine. It’s the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

This 1988-2010 Ford AU/BA/BF/EA/EB/ED Falcon & Fairlaine service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

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Pinion Oil Seal Replacement
NOTE: Refer to Special Tools in this section. Removal
1. Raise the vehicle on a hoist. Disconnect the drive shaft from the drive pinion flange after marking the drive shaft and pinion flange to ensure correct radial positioning on re-assembly. (Refer to Section 205-01.)
2. Mark the pinion flange and the pinion nut to establish bearing preload on re-assembly.
3. Hold the pinion flange using tool EN1205B and remove the self locking nut. As Loctite is used on the pinion nut, the torque required to release the nut will be greater than 200Nm.
4. Place a drain pan beneath the pinion housing.
5. Mark the ends of the pinion shaft and a pinion flange spline for correct re-alignment during installation.
6. Clean the pinion bearing housing around the oil seal to remove loose dirt and oil so that it does not fall into the front of the carrier housing during the removal or replacement procedure.
7. Remove the pinion flange using tool number E9258B. Under no circumstances should a hammer be used.
8. Remove the pinion oil seal by carefully prying it out with a suitable tool.
NOTE: All hardware must be correctly installed and
torqued to specification.
1. Check the mating splines on the pinion shaft and pinion flange for burrs and if necessary clean up with fine crocus cloth. Wipe the flange and shaft clean. Remove any Loctite thread locking compound from the pinion nut of flange thread.
2. Clean the oil seal seat. The lubricant return passage in the axle housing must be clear.
3. Lubricate the seal lips and the outside diameter with oil and install the seal, using the correct special tool. Seal location is from flush to 0.25 mm below the machined carrier face.
4. Align the pinion flange spline mark with the pinion shaft spline mark and start the flange onto the pinion splines by hand. A smear of lubricant on the pinion splines will assist in installation.
5. Install the pinion nut onto the pinion thread (without Loctite) and wind the nut down to pull the flange onto the pinion spline until no axial end play can be detected by hand in the pinion assembly. Remove the pinion nut.
6. Apply Loctite 262 Liquid Threadlocker to the pinion thread and reinstall the nut, tightening to 100Nm.