Axle Shaft

Removal

1. Raise vehicle to desired working height. Refer to Section 00-02. Remove wheels (1007) . Remove rear disc brake calipers (2552) and rear disc brake rotors (2C026) . Refer to Section 06-04.

2. Clean all dirt from area of carrier cover with a wire brush and/or cloth.

3. Drain rear axle lubricant by removing the axle housing cover (4033) .

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

7. Remove axle shaft from the rear axle housing (4010) , being careful not to damage the inner wheel bearing oil seal (1177) .

Installation

NOTE: Check for presence of rear axle shaft o-ring (4A332) on the spline end of the axle shaft and install if not present.

1. Carefully slide axle shaft into rear axle housing , without damaging rear wheel bearing (1225) or inner wheel bearing oil seal assembly. Start splines into differential side gear (4236) and push firmly until the button end of axle shaft can be seen in the differential case (4204) .

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

2. Install the rear axle shaft retaining u-washer on the button end of the axle shaft splines, then push the axle 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 the hole in the shaft with the differential pinion shaft lock pin hole. Install differential pinion shaft lock pin and tighten to 20-41 Nm (15-30 lb-ft).
   
   
   
   

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

    CAUTION: Ensure machined surfaces on both axle housing cover and rear axle housing are clean before installing the new silicone rubber. Inside of axle must be covered when cleaning the machined surface to prevent axle contamination. Tighten the axle housing cover bolts (4346) in a crosswise pattern to ensure uniform draw on axle housing cover .

4. Apply Silicone Rubber D6AZ-19562-AA or BA or equivalent meeting Ford specification ESE-M4G195-A and ESB-M4G72-A. Install axle housing cover and tighten axle housing cover bolts to 38-52 Nm (28-38 lb-ft). Tighten ratio tag cover bolt (two o'clock position) to 24-38 Nm (18-28 lb-ft).
   
   
   
   

5. Add Rear Axle Lubricant XY-90-QL E0AZ-19580 or equivalent meeting Ford specification ESP-M2C154-A until it is 6-14mm (0.250-0.562 inch) below bottom of fill hole. Add four ounces of Friction Modifier C8Z-19B546-A or equivalent meeting Ford specification EST-M2C118-A 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).