Axle Shaft: Service and Repair

Axle Shaft

Removal





1. 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 LH side of the luggage compartment. 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.

Turn the air suspension switch off.

2. NOTE: When removing the rear brake caliper in this procedure, it is not necessary to disconnect the hydraulic lines.

Remove the rear brake caliper and the brake disc.
^ Support the rear brake caliper with mechanics wire.





3. Position the rear brake anti-lock aside.
1 Remove the bolt.
2 Remove the sensor.





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. 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.

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





6. CAUTION: Do not damage the rubber O-ring in the U-washer groove.

Remove the U-washer.
1 Push the axle shaft inboard.
2 Remove the U-washer.





7. Reinstall the differential pinion shaft. 1 Push the axle shaft outboard. 2 Install the differential pinion shaft. 3 Install the differential pinion shaft lock bolt finger-tight.





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

Remove the axle shaft.

Installation





1. Lubricate the lip of the wheel bearing oil seal.
^ Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.





2. 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.

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





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

Install the axle shaft.





4. CAUTION: Do not damage the rubber O-ring in the U-washer groove.

Install the U-washer.
1 Position the U-washer on the button end of the axle shaft.
2 Pull the axle shaft outward to seat the U-washer in the side gear.





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 differential housing cover.
1 Position the cover.
2 Install the bolts.





7. Install the rear brake anti-lock sensor.
8. Install the brake disc.