Disassembly

Axle Assembly














Special Tool(s)





Material

Disassembly
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the rear axle assembly.








3. Drain the axle.

4. CAUTION: The machined surfaces on the differential housing and the differential housing cover must be clean and free of oil before applying the new Silicone Gasket and Sealant F7AZ-19554-EA meeting Ford specification WSE-M4G323-A4. Cover the inside of the axle before cleaning the machined surface to prevent contamination.

Remove the differential housing cover.





5. Mount the differential assembly in the special tool.





6. Install a Nm (inch lbs.) torque wrench on the differential drive pinion nut and record the torque necessary to maintain rotation of the differential pinion gear through several revolutions.





7. Index-mark the rear axle pinion flange to the differential pinion stem.

8. CAUTION: After removing the differential drive pinion nut, discard it. Use a new differential drive pinion nut for installation.





Use the special tool to hold the rear axle pinion flange while removing the differential drive pinion nut.





9. Using the special tool, remove the rear axle pinion flange.





10. Use a screwdriver to force up the metal flange of the rear pinion oil seal. Install gripping pliers and strike with a hammer to remove the rear pinion oil seal.
11. Remove the rear pinion oil seal slinger, outer pinion bearing and the drive pinion collapsible spacer.





12. Force up the metal flange on the halfshaft housing seal.





13. Install gripping pliers and strike with a hammer to remove the halfshaft housing seal from the housing.
14. Repeat for the other side.
15. Remove the selective snap ring, differential bearing shim and the differential bearing cups.
16. Remove the differential case assembly.
17. Remove the differential ring gear bolts, then the differential ring gear.





18. Using the special tools, remove the differential bearing.
^ Repeat for the other side.

19. NOTE: Drive the differential pinion shaft roll pin from the differential pinion shaft after the differential pinion shaft is removed from the differential case. Discard the differential pinion shaft roll pin.





If necessary, disassemble the differential case as follows:
1 Using a drift punch and a hammer, drive the differential pinion shaft roll pin into the differential pinion shaft until bottomed out. The differential pinion shaft roll pin will remain in the differential pinion shaft when the differential pinion shaft is removed from the differential case.
2 Remove the differential pinion shaft.
3 Remove the differential pinion gears and differential pinion gear thrust washers.
4 Remove the differential side gears and differential side gear thrust washers.
20. Remove the differential pinion gear.





21. Using the special tool and a suitable press, remove the inner pinion bearing.
1 Position the special tool under the inner pinion nearing.
2 Press the inner pinion bearing off of the differential pinion gear.
22. Using a drift punch and a hammer, remove the inner pinion bearing cup.





23. Using a drift punch and a hammer, remove the outer pinion bearing cup.
24. If necessary, remove the rear axle housing support insulator.
25. Inspect all components for wear or damage. Install new components as necessary.