Axle Shaft

Removal

1. Raise vehicle and remove rear wheels (1007) . Refer to Section 00-02. Remove rear disc brake caliper (2552) and rear disc brake rotor (2C026) . Refer to Section 06-04.

2. Clean all dirt from area of axle housing cover (4033) with a wire brush and/or cloth.

3. Drain rear axle lubricant by removing the axle housing cover .

4. Remove differential pinion shaft lock pin (4241) and differential pinion shaft (4211) .
   
   
   
   

    CAUTION: Damage to rear brake anti-lock sensor (2C190) may occur if rear brake anti-lock sensor is not removed before axle shaft (4234) .

5. Carefully remove rear brake anti-lock sensor , before removing axle shaft .
   
   
   
   

6. Push flanged end of axle shafts toward center of vehicle and remove rear axle shaft retaining u-washer (4N237) from button end of the axle shaft .
   
   
   
   

7. Remove axle shaft from housing, being careful not to damage the inner wheel bearing oil seal (1177) .

Installation

 CAUTION: Care must be taken not to let axle shaft splines damage inner wheel bearing oil seal or rear wheel bearing (1225) assembly.

1. Carefully slide the axle shaft into the rear axle housing (4010) , without damaging rear wheel bearing or inner wheel bearing oil seal assembly. Start the splines into the differential side gear (4236) and push firmly until the button end of the axle shaft can be seen in the differential case (4204) .

2. Install the rear axle shaft retaining u-washer on the button end of the axle shaft splines, then push the shaft outboard until the shaft splines engage and the rear axle shaft retaining u-washer seats in the counterbore of the differential side gear .

    CAUTION: Differential pinion shaft lock pin must be tightened to specification using Stud and Bearing Mount E0AZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1.

3. Position the differential pinion shaft through the differential case and differential pinion gears (4215) aligning hole in shaft with differential pinion shaft lock pin hole. Install differential pinion shaft lock pin . Tighten to 20-41 Nm (15-30 lb-ft).
   
   
   
   

    CAUTION: Make sure machined surfaces on both axle housing cover and rear axle housing are clean before installing new silicone sealant. Inside of rear axle housing must be covered when cleaning machined surface to prevent axle contamination. Tighten axle housing cover bolt (4346) in a cross-wise pattern to ensure uniform draw on axle housing cover .

4. Apply Silicone Rubber D6AZ-19562-AA or -BA or equivalent meeting Ford specification ESB-M4G92-A and ESE-M4G195-A. Install axle housing cover and tighten axle housing cover bolt to 38-52 Nm (28-38 lb-ft).

   NOTE: Axle housing cover must be installed within 15 minutes of application of silicone rubber or new silicone rubber must be applied.

   
   
   
   
   

5. Add Rear Axle Lubricant XY-90-QL E0AZ-19580-AA or equivalent meeting Ford specification ESP-M2C154-A until it is 6-14mm (0.250-0.562 inch) below bottom of fill hole. Add 118 ml (4 oz) of Friction Modifier C8Z-19B546-A or equivalent for traction-lok axles. Install fill plug and tighten to 20-41 Nm (15-30 lb-ft).

6. Ensure rear axle housing vent (4022) is not plugged with any debris.

7. Install rear brake anti-lock sensor and tighten to 4.5-6.8 Nm (40-60 lb-in).