Axle Shaft: Installation

All vehicles 

1. Lubricate the lip of the wheel bearing oil seal with grease.
CAUTION: Do not damage the wheel bearing oil seal.
Fig 1: Installing Axle Shafts
Courtesy of FORD MOTOR CO.
2. Install the two axle shafts.
CAUTION: Do not damage the rubber O-rings in the U-washer grooves.
3. Install the U-washers.
   1. Position the two U-washers on the button end of the axle shafts.
   2. Pull the axle shafts outward.
      Fig 2: Installing U-Washers

      Courtesy of FORD MOTOR CO.
NOTE: If a new pinion shaft lock bolt is unavailable coat the threads with threadlock prior to installation.
4. Install the differential pinion shaft.
   1. Align the hole in the differential pinion shaft with the case lock bolt hole.
   2. Install a new differential pinion shaft lock bolt.
      Fig 3: Identifying Tightening Torque For Installing Differential Pinion Shaft Lock Bolt

      Courtesy of FORD MOTOR CO.

      Vehicles with drum brakes 

5. Install the rear brake drums.

   Vehicles with disc brakes 

6. Install the rear brake disc.
   Fig 4: Installing Rear Brake Disc

   Courtesy of FORD MOTOR CO.
7. Install the rear disc brake caliper. Refer to REAR DISC BRAKE CALIPER & PADS .
NOTE: Clean the gasket mating surface of the rear axle and the differential housing cover.
Fig 5: Applying Continuous Bead Of Sealant To Differential Housing Cover
Courtesy of FORD MOTOR CO.
8. Apply a new continuous bead of sealant to the differential housing cover.
NOTE: The differential housing cover must be installed within 15 minutes of application of the silicone, or new sealant must be applied. If possible, allow one hour before filling with lubricant to make sure the silicone sealant has correctly cured.
9. Install the differential housing cover.
   1. Install the differential housing cover.
   2. Install the 10 differential housing cover bolts.
      Fig 6: Identifying Tightening Torque Of Differential Housing Cover Bolts

      Courtesy of FORD MOTOR CO.
10. Fill the rear axle housing (4010) with 2.37 liters (5 pints) with the specified lubricant.
WARNING: Always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel (1007) or the surface of the wheel hub or brake drum or disc that contacts the wheel. Installing wheels without correct 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.
11. Clean the wheel hub and mounting surfaces.
12. Install the tire and wheel assembly.