Axle Housing

Removal

1. Raise vehicle on a hoist and 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 the 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 the 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-washer (4N237) .
   
   
   
   

7. Remove axle shafts .

8. Remove four retaining nuts from each rear wheel disc brake shield (2C028) and wire the rear wheel disc brake shield to underbody.

   NOTE: Mark driveshaft (4602) at rear axle universal joint flange (4851) . Refer toFlange Yoke Seal Removal , Step 2.

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

10. Support 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: The rear axle housing vent (4022) is secured to the rear axle housing assembly. At assembly, apply Stud and Bearing Mount E0AZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to the thread to ensure retention.

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

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

14. Remove retaining nut and bolts and disconnect the rear suspension arm and bushing (5500) from the mountings on the axle housing ear brackets. If equipped, disconnect quad shock from rear axle damper body bracket (4A491) .

15. Lower rear axle housing assembly until the 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 using Axle Tube Bearing Replacer T78P-1225-A.
   
   
   
   

3. Install two new inner wheel bearing oil seals (1177) 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 the rear suspension lower arms 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 the mounting ears on rear axle housing . Connect rear suspension lower arms to rear axle housing . Tighten rear suspension arms and bushing 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. Install rear wheel disc brake shields on axle housing flanges (no gaskets required).

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

11. Connect driveshaft to rear axle universal joint flange . Install bolts. Tighten to 95-130 Nm (70-95 lb-ft).
    
    
    
    

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

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

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

14. Coat threads of differential pinion shaft lock pin with Stud and Bearing Mount E0AZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 and install differential pinion shaft and differential pinion shaft lock pin . Tighten lock bolt to 20-41 Nm (15-30 lb-ft).
    
    
    
    

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

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

17. Install axle housing cover using Silicone Rubber D6AZ-19562-AA or BA or equivalent meeting Ford specifications ESE-M4G195-A and ESB-M4G92-A and tighten axle housing cover bolt (4346) to 38-52 Nm (28-38 lb-ft).

    NOTE: Axle housing cover bolt at two o'clock position (at ratio tag location) is to be tightened to 24-38 Nm (18-28 lb-ft) for metal axle housing covers .

    
    
    
    
    

     CAUTION: Overfilling axle will cause axle leak.

18. Add Rear Axle Lubricant E0AZ-19580AA or equivalent until it is 6-14mm (.250-.562 inch) below bottom of the fill hole. Add four ounces of Friction Modifier C8AZ-19B546-A or equivalent for Traction-Lok axles. Install 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.