Axle Shaft: Service and Repair
REMOVAL1. Raise vehicle to the desired working height, and remove the rear wheel and tire assemblies. Remove the brake drums.
NOTE: Whenever a plastic axle housing cover is removed, it must be replaced with a new cover and bolts. Steel axle housing covers may be reused after thorough cleaning and removing all old gasket material from cover and carrier face.
NOTE: For 3.03:1, 3.27:1 and 3.45:1 ratio axles, refer to Steps 4-6. For 3.73:1 and 4.10:1 ratio axles, refer to Steps 7-10.
2. Clean all dirt from the area of carrier axle housing cover with a wire brush and/or cloth.
3. Remove axle housing cover and drain lubricant.
4. Remove differential pinion shaft lock bolt and differential pinion shaft. The pinion gears may be left in place. Once the axle shafts are removed, reinstall the differential pinion shaft and differential pinion shaft lock bolt.
5. Push the flanged end of the axle shafts toward the center of the vehicle and remove the U-washer from the button end of the axle shaft.
6. Remove the axle shaft from the housing, being careful not to damage the inner wheel bearing oil seal.
CAUTION: Always remove axle shafts completely from housing or damage to inner wheel bearing oil seal may result.
7. For 3.73:1 and 4.10:1 ratio rear axle assemblies, remove the differential pinion shaft lock bolt.
8. Place hand behind differential case and push out part of differential pinion shaft until the step on the shaft contacts the ring gear.
9. Remove the U-washer from the axle shafts
10. Remove the axle shafts from the rear axle housing, being careful not to damage the inner wheel bearing oil seal.
INSTALLATION
NOTE: To permit installation of axle shaft on 3.73:1 and 4.10:1 axle ratios, make sure the step in the differential pinion shaft contacts the ring gear.
1. Carefully slide the axle shaft into the axle housing. Start the splines into the differential side gear and push firmly until the button end of the axle shaft can be seen in the differential case.
CAUTION: When performing the next step, care must be taken not to let the axle shaft splines damage the oil seal or wheel bearing.
2. Install the U-washers on the button end of the axle shaft splines, then pull the axle shaft outboard until the splices engage and the U-washer seats in the counterbore of the differential side gear.
3. Position the differential pinion shaft through the differential case and pinion gears, aligning the hole in the shaft with the lock bolt hole. Install differential pinion shaft lock bolt and tighten to 20-40 Nm (15-30 ft. lbs.).
CAUTION: Replace differential pinion shaft lock bolt after removal. If new bolt is not available, thoroughly clean threads of used bolt and coat with Threadlock and Sealer EOAZ-19554-A or equivalent meeting Ford specification WSK-M2G351-A5 before installation.
4. Clean the cover thoroughly. Apply a new continuous bead of Silicone Rubber Sealant D6AZ-19562-BA or equivalent meeting Ford specification ESB-M4G92-A or ESE-M4G195-A to the axle housing cover.
CAUTION: Make sure machined surface on carrier is clean before installing the cover. Inside of rear axle must be covered when cleaning the machined surface to prevent axle contamination.
5. Tighten cover screws to 38-52 Nm (28-38 ft. lbs.). Cover assembly must be installed within 15 minutes of application of the silicone or new sealant must be applied.
6. Add Rear Axle Lubricant XY-80W90-QL or equivalent WSP-M2C197-A until it is 6-14 mm (1/4-9/16 inch) below bottom of fill hole. Add four ounces of Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A for Traction-Lok rear axle assemblies. Install fill plug and tighten to 20-41 Nm (15-30 ft. lbs.).
Make sure axle housing vent is not plugged with debris.
. Install the brake drums, wheels and tires. Tighten lug nuts to 115-156 Nm (85-115 ft. lbs.).