Axle Housing

Removal

1. Raise vehicle on a hoist. Position safety stands under the rear frame crossmember. Refer to Section 00-02.

2. Drain lubricant from the axle by removing axle housing cover (4033).

3. Remove wheels (1007) , rear disc brake calipers (2552) and rear disc brake rotors (2C026) . Refer to Section 06-04.

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

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

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

6. Push axle shafts inward to remove rear axle shaft retaining u-washers (4N237) .
   
   
   
   

7. Remove axle shafts .

8. Remove bolt retaining brake junction block to axle housing cover . Remove brake hose support bracket (2082) from clips and position out of the way.

   NOTE: Mark driveshaft centering socket yoke (4782) and rear axle universal joint flange (4851) . Refer toFlange Yoke Seal Removal, Step 2.

9. Disconnect driveshaft (4602) at rear axle universal joint flange and wire it to the underbody.

10. Support the rear axle housing (4010) with jackstands or a hoist.

11. Disengage rear brake hose (2282) from clips that retain the rear brake hose to the rear axle housing .

    NOTE: Some rear axle housing vents (4022) may be secured to the rear axle housing through the brake junction block. At assembly, apply Threadlock and Sealer E0AZ-19554-AA or equivalent meeting Ford specification ESE-M4G167-A5 to the thread to ensure retention.

12. Disconnect rear axle housing vent from rear axle housing .

13. Disconnect lower shock absorber studs from rear shock absorber lower mounting bracket (18164) on rear axle housing .

14. Remove the retaining nut and bolts and disconnect the rear suspension arm and bushing (5500) from the mountings on the axle housing ear brackets.

15. Lower rear axle housing assembly until rear springs (5560) are released. Lift out rear springs .

16. Remove nuts and bolts that connect rear suspension lower arms (5A649) to rear axle housing . Disconnect both rear suspension lower arms from the rear axle housing .

17. Lower rear axle housing and remove it from the vehicle.

Installation

1. Transfer all components from old rear axle housing to new rear axle housing as outlined.

2. Install new rear wheel bearings (1225) into new rear axle housing bores using Axle Tube Bearing Replacer T78P-1225-A.
   
   
   
   

    CAUTION: Installation of rear wheel bearing or inner wheel bearing oil seal (1177) without proper tool may result in an early rear wheel bearing or inner wheel bearing oil seal failure. If inner wheel bearing oil seal becomes cocked in bore during installation, remove it and install a new one.

3. Install new inner wheel bearing oil seals into housing bores using Axle Tube Seal Replacer T78P-1177-A. Apply Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B between the lips of the inner wheel bearing oil seal .
   
   
   
   

4. Position new rear axle housing under vehicle and raise rear axle housing with a hoist or jack. Connect rear suspension lower arm to their mounting brackets on rear axle housing . (Do not tighten bolts and nuts at this point.)

5. Position rear springs in area provided.

6. Raise rear axle housing into position.

7. Connect rear suspension arm and bushings to mounting ears on rear axle housing . Connect rear suspension lower arm to rear axle housing . Tighten rear suspension arm and bushing arm bolts to 95-135 Nm (70-100 lb-ft). Tighten rear suspension lower arm retaining bolts to 95-135 Nm (70-100 lb-ft).

8. Position rear brake hoses to the rear axle housing and secure with retaining clips. Position and secure brake junction block to the rear axle housing cast boss. Tighten to 14-24 Nm (10-18 lb-ft).

9. Connect lower shock absorber studs to rear shock absorber lower mounting bracket on the rear axle housing . Install retaining nuts and tighten to 76-104 Nm (56-77 lb-ft).

10. Connect the driveshaft to the rear axle universal joint flange . Install bolts and nuts and tighten to 95-130 Nm (70-95 lb-ft).
    
    
    
    

     CAUTION: Do not damage rear wheel bearing or inner wheel bearing oil seal .

11. Slide the axle shafts into the rear axle housing until splines enter the differential side gears (4236) .

12. Push the axle shafts inward, and install the rear axle shaft retaining u-washer at the end of each shaft spline. Pull shafts outboard until each rear axle shaft retaining u-washer enters the recess in the differential side gears .
    
    
    
    

     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.

13. Install the differential pinion shaft and the differential pinion shaft lock pin. Tighten to 20-41 Nm (15-30 lb-ft).
    
    
    
    

14. Install rear disc brake rotors and rear disc brake calipers . Refer to Section 06-04.

15. Install wheels . Tighten wheel hub bolt nuts (1012) to 115-142 Nm (85-105 lb-ft).

16. Install axle housing cover using Silicone Rubber D6AZ-19562-AA or BA (ESB-M4G92-A or ESE-M4G195-A) or equivalent. Tighten axle housing cover bolts (4346) to 38-52 Nm (28-38 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 axle must be covered when cleaning machined surface to prevent axle contamination. Tighten axle housing cover bolt in a crosswise pattern to ensure uniform draw on axle housing cover .

    
    
    
    
    

17. Install the brake junction block on the axle housing cover . Tighten retaining bolt to 14-24 Nm (11-17 lb-ft). Install rear brake hoses in retaining clips. Bleed brake system, refer to Section 06-00.

18. Add Rear Axle Lubricant E0AZ-19580-AA or equivalent unti it is 6-14mm (0.250-0.562 inch) below bottom of filler hole. Add 118 ml (4 oz) of Friction Modifier C8AZ-19B546-A or equivalent for traction-lok axles. Insert fill plug and tighten to 20-41 Nm (15-30 lb-ft).

19. Ensure rear axle housing vent is not plugged with debris.

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

21. Road test vehicle.