Axle Shaft: Service and Repair

Removal

CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and the rear wheel bearings.





1. Loosen the lug nuts.
1. Remove the center cap.
2. With the weight of the vehicle on the wheels, loosen the lug nuts.

WARNING: When equipped with rear air springs, the electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations.

2. Raise and support the vehicle.





3. Remove the wheel and tire assembly.
1. Remove the lug nuts.
2. Remove the wheel and tire assembly.
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4. Remove the differential housing cover.
1. Remove the 10 differential housing cover bolts and drain the lubricant from the rear axle housing.
2. Remove the differential housing cover.
5. Remove the rear brake anti-lock sensor.
6. Remove the brake discs.

CAUTION: Once the differential pinion shaft has been removed, turning the differential case or an axle shaft can cause the differential pinion gears to fall out of the assembly. This can result in chipped or damaged components.





7. Remove the differential pinion shaft.
1. Remove the differential pinion shaft lock bolt.
2. Remove the differential pinion shaft.

CAUTION: Do not damage the rubber O-rings in the U-washer grooves.





8. Remove the U-washers.
1. Push the axle shafts inboard.
2. Remove the U-washers.





9. Reinstall the differential pinion shaft.
1. Install the differential pinion shaft.
2. Install the differential pinion shaft lock bolt finger-tight.

CAUTION: Do not damage the inner wheel bearing oil seal.





10. Remove the two axle shafts.

Installation





1. Lubricate the lip of the inner wheel bearing oil seal.
^ Use Premium Long-Life Grease XG- I -C or equivalent meeting Ford specification ESA-MIC75-B.

CAUTION: Once the differential pinion shaft has been removed, turning the differential case or an axle shaft can cause the differential pinion gears to fall out of the assembly. This can result in chipped or damaged components.





2. Remove the differential pinion shaft.
1. Remove the differential pinion shaft lock bolt.
2. Remove the differential pinion shaft.

CAUTION: Do not damage the inner* r wheel bearing oil seal.





3. Install the two axle shafts.

CAUTION: Do not damage the rubber
O-rings in the U-washer grooves.





4. Install the U-washers.
1. Position the two U-washers on the button end of the axle shaft.
2. Pull the axle shafts outward to seat the U-washers in the side gears.





5. Install the differential pinion shaft.
1. Align the hole in the differential pinion shaft with the lock bolt hole.
2. Install the differential pinion shaft lock bolt.
6. Install the brake discs.
7. Install the rear brake anti-lock sensor.
8. Install the differential housing cover and fill the rear axle housing with 1.8 liters (3.75. pints) of Thermally Stable Rear Axle Lubricant XY-8OW90-QL or equivalent meeting Ford specification WSP-M2C197-A.

WARNING: Always remove any corrosion, dirt or foreign material that may be present on the mounting surfaces of the wheel or the surface of the wheel hub or rear brake disc that contacts the wheel. Installing wheels without proper metal-to-metal contact at the wheel mounting surfaces can cause the lug nut to loosen and the wheel to come off while the vehicle is in motion, causing loss of control.

9. Clean the wheel hub and mounting surfaces.

NOTE: If equipped with air suspension, reactivate the system by turning the air suspension switch on.





10. Install the tire and wheel assembly.
1. Position the tire and wheel assembly.
2. Install the lug nuts and lower the vehicle.
3. Tighten the lug nuts.
4. Install the center cap.
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