Axle Housing Removal and Installation

Special Tools And Equipment:

Special Tool(s)

Removal





1. CAUTION: The vehicle must be on level ground and at curb height.

Mark the rear shock absorbers relative to their protective sleeve.
^ During installation, raise the suspension to this reference mark before tightening the suspension component fasteners.
2. Raise and support the vehicle.
3. Remove the rear wheel and tire assemblies.
4. Remove the mufflers.





5. Remove the Pinion nose crossmember.

Part 1 Of 2:

Part 2 Of 2:

6. CAUTION: Index-mark the driveshaft flange and rear axle pinion flange to maintain initial balance during installation.

CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the yoke from the flange. Pry only in the area shown, with a suitable tool, to disconnect the yoke from the flange.

Disconnect and position the driveshaft out of the way.





7. NOTE: The following halfshaft and knuckle assembly removal steps apply to both sides of the vehicle.

Disconnect the parking brake rear cables.





8. Remove the parking brake rear cable and conduit from the routing clip bolts.





9. Disconnect the parking brake rear cable from the parking brake lever.





10. Remove the clip from the rear disc brake caliper.





11. Remove the parking brake rear cable and conduit from the rear disc brake caliper.





12. Separate the parking brake cable and conduit from the knuckle.





13. Remove the rear brake caliper and support bracket from the knuckle as an assembly. Wire the caliper and support bracket assembly out of the way.





14. Remove the brake disc.





15. Remove the rear brake anti-lock sensor and position it aside.
16. Support the lower suspension arm and bushing with a jack stand.





17. Remove the nuts and disconnect the stabilizer bar links.
^ Discard the nuts.





18. Remove and discard the cotter pin and nut.





19. CAUTION: Do not strike the toe link or the knuckle to disconnect the toe link from the knuckle.

Using the special tool, disconnect the toe link from the knuckle.





20. Mark the cam bolt position relative to the upper suspension arm and bushing.





21. Disconnect the knuckle from the lower suspension arm and bushing.
1 Remove and discard the nut and bolt.
2 Disconnect the knuckle from the lower suspension arm and bushing.





22. NOTE: Mark the new cam bolt in the same position as the old one for assembly reference before discarding the old bolt.

Disconnect the knuckle from upper suspension arm and bushing.
1 Remove and discard the nut and bolt.
2 Disconnect the knuckle from the upper suspension arm and bushing.





23. CAUTION: The crown on the tool forks must face away from the differential housing. Position the special tool correctly between the CV joint and the differential housing so as not to damage the differential seal.

Using the special tool, exert enough pressure to overcome the circlip and separate the CV joint from the differential side gear.





24. Install the special tool.





25. Remove the halfshaft and knuckle assembly from the vehicle.





26. Insert the special tool into the housing bore.
27. Remove the other halfshaft and knuckle assembly as described in the previous steps.
28. Support the differential housing with a transmission Jack.





29. Remove the bolts.





30. Remove the nuts and bolts.

31. CAUTION: Do not damage the axle vent hose.

Lower the rear axle assembly from the vehicle.





32. If removal of the mounting bushings is necessary, remove them by hand.

Installation





1. Install the bushings, if removed.
2. Using the transmission jack, raise the rear axle assembly into position.





3. Install the bolts and nuts.





4. Install the bolts.





5. Install the pinion nose crossmember.





6. NOTE: The following halfshaft and knuckle assembly installation steps apply to both sides of the vehicle.

Remove the special tool.





7. CAUTION: Differential seal damage will occur if installing the halfshaft without the special tool.

Install the special tool.





8. Position the halfshaft for installation.





9. Seat the CV joint stub shaft in the differential side gear.
1 Slide the stub shaft into the differential housing until the shaft splines are past the differential seal.
2 Remove the special tool.
3 Align the stub shaft splines and the side gear splines, and slide the stub shaft into the gear until it seats.
^ When seated, the axle circlip will lock the stub shaft in the differential side gear. Check the circlip engagement by attempting to pull the inboard CV joint out of the differential side gear. If the circlip has not seated, push the CV joint inward until the circlip is fully engaged in the differential side gear.





10. CAUTION: Do not tighten the fastener at this time.

Connect the knuckle to the upper suspension arm and bushing.
1 Position the knuckle.
2 Install the new cam bolt and nut.





11. CAUTION: Do not tighten the fastener at this time.

Connect the knuckle to the lower suspension arm and bushing.
1 Position the knuckle.
2 Install the new bolt and nut.





12. Connect the toe link to the knuckle.
1 Position the toe link.
2 Install the new nut.
3 Install the new cotter pin.





13. Connect the stabilizer bar links.
^ Install new nuts.
14. Install the other halfshaft and knuckle assembly, toe link, and shock absorber as described in the previous steps.





15. Raise the suspension until the shock absorbers compress to the previously established alignment mark (curb height).





16. Tighten the nut.





17. Align the marks on the cam bolt and the upper suspension arm and bushing, and tighten the nut
18. Repeat the two previous steps for the other knuckle.
19. Lower the suspension and remove the jack stands.





20. Apply Anti-Seize Lubricant to the rear brake anti-lock sensors where they contact the axle housing and install the anti-lock sensors.
^ Use High Temperature Nickel Anti-Seize Lubricant F6AZ-9L494-AA or equivalent meeting Ford specification ESE-M12A4-A.





21. Install the brake disc.





22. Install the rear brake caliper and support bracket.





23. Position the parking brake cable and conduit.





24. Install the parking brake rear cable and conduit to the rear disc brake caliper.





25. Install the clip to the rear disc brake caliper.





26. Connect the parking brake rear cable to the parking brake lever.





27. Install the parking brake rear cable and conduit routing clip bolt.





28. Connect the parking brake rear cable.
29. Repeat the three previous steps for the brake components on the other side of the vehicle.





30. CAUTION: Align the index-marks.

CAUTION: Install the driveshaft with new bolts. If new bolts are not available, apply Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5 to the threads of the original bolts.

CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion flange pilot. To make sure that the yoke seats squarely on the flange, tighten the bolts evenly in a cross pattern as shown.

Connect the driveshaft and install the bolts.
31. Install the mufflers.
32. Install the wheels and tires.





33. CAUTION: If refilling the rear axle, first add 118 ml (4 oz) of Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A.

Check the lubricant level.
^ If necessary, fill the rear axle housing to the level shown with SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. The refill capacity is 1.23 - 1.37 liters (2.6 - 2.9 pints).
34. Lower the vehicle.
35. Check, and adjust the wheel alignment as necessary.