Section 05-02A: Axle, Integral Carrier—7.5 Inch Ring Gear
1993 Mustang Workshop Manual
REMOVAL AND INSTALLATION

Axle Housing

Tools Required:

 

Removal

  1. Raise vehicle on a hoist. Position safety stands under the rear frame crossmember. Refer to Section 00-02.
  1. Drain lubricant from the axle by removing cover.
  1. Remove wheels and brake drums.
  1. Remove lock bolt from the pinion shaft and remove shaft.



  1. Push axle shafts inward to remove C- locks.



  1. Remove axle shafts.
  1. Remove bolt retaining brake junction block to rear cover. Remove brake lines from clips and position out of the way.
  1. Remove four retaining nuts from each backing plate and wire backing plate to underbody.

    NOTE: Mark driveshaft yoke and companion flange. Refer to Pinion Seal Removal, Step 2.

  1. Disconnect driveshaft at companion flange and wire it to the underbody.
  1. Support the axle housing with jackstands or a hoist.
  1. Disengage brake line from clips that retain the line to the axle housing.

    NOTE: Some axle vents may be secured to the housing assembly through the brake junction block. At assembly, thread locker is applied to the thread to ensure retention. Upon installation, Threadlock and Sealer E0AZ-19554-AA (ESE-M4G167-A2) or equivalent must be reapplied.

  1. Disconnect vent from rear axle housing.
  1. Disconnect lower shock absorber studs from mounting brackets on axle housing.
  1. Remove the retaining nut and bolts and disconnect the upper arms from the mountings on the axle housing ear brackets.
  1. Lower axle housing assembly until coil springs are released. Lift out coil springs.
  1. Remove nuts and bolts that connect suspension lower arms to axle housing. Disconnect both arms from the axle housing.
  1. Lower axle housing and remove it from the vehicle.
 

Installation

  1. Transfer all components from old housing to new housing and make necessary adjustments as outlined.
  1. Install new axle shaft bearings into new axle housing using Axle Tube Bearing Replacer T78P-1225-A.



     CAUTION: Installation of bearing of seal assembly without proper tool may result in an early bearing or seal failure. If seal becomes cocked in bore during installation, remove it and install a new one.

  1. Install two new wheel seals using Axle Tube Seal Replacer T78P-1177-A. Apply Premium Long-Life Grease XG-1-C (ESA-M1C75-B) or equivalent between the lips of the seal.



  1. Position new axle housing under vehicle and raise axle with a hoist or jack. Connect suspension lower arms to their mounting brackets on axle housing. (Do not tighten bolts and nuts at this point.)
  1. Position rear coil springs in area provided.
  1. Raise housing into position.
  1. Connect upper arms to mounting ears on housing. Connect lower suspension arms to axle housing. Tighten upper suspension arm bolts to 95-135 Nm (70-100 lb-ft). Tighten lower arm retaining bolts to 95-135 Nm (70-100 lb-ft).
  1. Position brake lines to the axle housing and secure with retaining clips. Position and secure brake junction block to the housing cast boss. Tighten to 14-24 Nm (10-18 lb-ft).
  1. Install the brake backing plates on the axle housing flanges (no gaskets required and) and tighten to 27-54 Nm (20-39 lb-ft).
  1. Connect lower shock absorber studs to mounting bracket on the axle housing. Install retaining nuts and tighten to 76-104 Nm (56-77 lb-ft).
  1. Connect the driveshaft to the companion flange. Install bolts and nuts and tighten to 95-130 Nm (70-95 lb-ft).



     CAUTION: Do not damage wheel bearing seal.

  1. Slide the rear axle shafts into the housing until splines enter the side gears.
  1. Push the axle shafts inward, and install the C-lock at the end of each shaft spline. Pull shafts outboard until each C-lock enters the recess in the side gears.



     CAUTION: Lock bolt must be tightened to specification using Stud and Bearing Mount E0AZ-19554-BA (ESE-M4G167-A2) or equivalent.

  1. Install the pinion shaft and the pinion shaft lock bolt. Tighten to 20-41 Nm (15-30 lb-ft).



  1. Install rear brake drums.
  1. Install wheels and tires.
  1. Install carrier cover using Silicone Rubber D6AZ-19562-AA or BA (ESB-M4G92-A or ESE-M4G195-A) or equivalent. Tighten retaining bolts to 38-52 Nm (28-38 lb-ft).

     CAUTION: Make sure machined surfaces on both cover and carrier are clean before installing new silicone sealant. Inside of axle must be covered when cleaning machined surface to prevent axle contamination. Tighten cover bolts in a crosswise pattern to ensure uniform draw on cover.





  1. Install the brake junction block on the carrier cover. Tighten retaining bolt to 14-24 Nm (11-17 lb-ft). Install brake lines in retaining clips.
  1. Fill axle with lubricant until fluid level is within 6-14mm (1/4-9/16-inch) below bottom of filler hole. Be sure the axle is in operating position. Install fill plug. Tighten to 20-41 Nm (15-30 lb-ft).
  1. Ensure axle vent is not plugged with debris.
  1. Road test vehicle.


Suspension





Item Part Number Description
1A 384485 Nut
2 38563 (Sedans)
3 N800239 Washer
4 N800240 Washer
5 18080 Shock Assy
6B N801623 Bolt (2 Req'd)
7 N801616 Washer (2 Req'd)
8 N801627 Nut (2 Req'd)
9 5536 Insulator (2 Req'd)
10 5538 Lower Control Arm Assy
11C N802293-S101 Bolt (2 Req'd)
12 5560 Install Pigtail in Direction Shown
13D N800933-S100 Bolt
14 5500 Upper Control Arm Assy
15 18A192 Insulator
16 4730 Jounce Bumper
17 N800937-S100 Nut (2 Req'd)
18D N8009325-S100 Bolt (2 Req'd)
19 5A638 Bushing (2 Req'd)
20 N800937-S100 Nut (2 Req'd)
21C N800932-S100 Bolt (2 Req'd)
A Tighten to 26-35 Nm (19-26 Lb-Ft)
B Tighten to 76-104 Nm (56-77 Lb-Ft)
C Tighten to 104-142
Nm (77-105 Lb-Ft)
D Tighten to 95-135 Nm (70-100 Lb-Ft)