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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 383 (Rear Drive Axle/Differential 7.5-Inch Ring Gear) >> In-Vehicle Repair >> Axle Shaft >> Installation

Axle Shaft: Installation

WARNING: This page is about a different car, the 2002 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION: Make sure the machined surfaces on both the rear axle housing and the differential housing cover are clean and free of oil before installing the new silicone sealant. The inside of the rear axle (4001) must be covered when cleaning the machined surface to prevent contamination.
  1. Clean the gasket mating surface of the rear axle and the differential housing cover.
  2. Lubricate the lip of the wheel bearing oil seal with grease.
    3. CAUTION: Do not damage the wheel bearing oil seal.
    Fig 1: Installing Axle Shaft
    G03434186Courtesy of FORD MOTOR CO.
  3. Install the two axle shafts.
    4. CAUTION: Do not damage the rubber O-rings in the axle shaft grooves.
    Fig 2: Installing U-Washer
    G03434187Courtesy of FORD MOTOR CO.
  4. Install the U-washers.
    1. Position the two U-washers on the button end of the axle shafts.
    2. Pull the axle shafts outward.
    5. NOTE: If a new pinion shaft lock bolt is unavailable, coat the threads with threadlock and sealer prior to installation.
    Fig 3: Installing Differential Pinion Shaft
    G03434188Courtesy of FORD MOTOR CO.
  5. 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.
  6. Install the rear brake drums. For additional information, REFER to DISC & DRUM .
  7. Apply a new continuous bead of sealant of the specified thickness to the differential housing cover.
    Fig 4: Applying Sealant To Differential Housing Cover
    G03434189Courtesy of FORD MOTOR CO.
    8. 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.
    Fig 5: Installing Differential Housing Cover
    G03434190Courtesy of FORD MOTOR CO.
  8. Install the differential housing cover.
    1. Install the different housing cover.
    2. Install the 10 differential housing cover bolts.
  9. Fill the rear axle housing with 2.4 liters (5 pints) of lubricant.
  10. Install the wheels and tires. For additional information, refer to WHEELS & TIRES .
  11. Lower the vehicle.
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