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How hard is it to replace the pionion seal on a 2000 EB Expedition and does anyone know the procedure to do so? I need to replace axle seal on passengers side, rear pads and parking brake shoes. Leaking seal sure made a mess!!
I had the same thing happen on my 00 EB; but it was the rear axle seal, supposedly common failure on these trucks. The seal gets worn fast due to the seal flange getting corrosion and tearing at the seal. Diff oil got all over the parking brake and brakes (right rear only). The dealer replaced it, about $600 total, they pulled only the one axle. One thing you may need to do to follow up with the repair is to ensure they put the oil additive in with the new synth diff oil; they claim to have put the additive in and charged me for it but I still had problems with the chattering in the LSD clutch plates. I went ahead and added 2-4 oz of the additive myself and there's been no problem since. I also discovered that the vent tube connected to the axle on the left side (and runs up to the wheel well) was completely blocked. You might want to check that too, it can affect the internal 'pressure' that is loaded in the diff and axles and can accelerate how fast that axle seal blows oil out when its bad. That axle seal repair is expensive.
I didn't realize you needed to remove the axles to replace a pinion seal. On my 2K Navi I just removed the nut, used a puller to get the pinion off, pryed out the seal, seated a new one, put the pinion back on, and tightened down a new nut.
Officially I think you are supposed to removed the gears from the case and use an inch pounds torque wrench to get the proper loading on the pinion bearing, but the approach I took is the same one my dealer techs use.