Axle Housing: Removal

CAUTION: The vehicle must be on level ground and at curb height.

Fig 1: Identifying Reference Mark For Raising Suspension

Courtesy of FORD MOTOR CO.

Mark the rear shock absorbers relative to their protective sleeve.
- During installation, raise the suspension to this reference mark before tightening the suspension component fasteners.
Raise and support the vehicle. For additional information, refer to JACKING & HOISTING .
Remove the rear wheel and tire assemblies.
Remove the mufflers. For additional information, refer to EXHAUST SYSTEM .

CAUTION: Index-mark the driveshaft flange and rear axle pinion flange to maintain initial balance during installation.

CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the yoke from the flange. Pry only in the area shown, with a suitable tool, to disconnect the yoke from the flange.

Fig 2: Removing Driveshaft/Pinion Flange Bolts

Courtesy of FORD MOTOR CO.

Fig 3: Disconnecting Yoke From Flange

Courtesy of FORD MOTOR CO.

Disconnect and position the driveshaft out of the way.

NOTE: The following halfshaft and knuckle assembly removal steps apply to both sides of the vehicle.

Fig 4: Disconnecting Parking Brake Rear Cables

Courtesy of FORD MOTOR CO.

Disconnect the parking brake rear cables.
Remove the parking brake rear cable and conduit from the routing clip bolts.

Fig 5: Identifying Routing Clip Bolts
Courtesy of FORD MOTOR CO.
Disconnect the parking brake rear cable from the parking brake lever.

Fig 6: Disconnecting Parking Brake Rear Cable From Parking Brake Lever
Courtesy of FORD MOTOR CO.
Remove the clip from the rear disc brake caliper.

Fig 7: Removing Clip From Rear Disc Brake Caliper
Courtesy of FORD MOTOR CO.
Remove the parking brake rear cable and conduit from the rear disc brake caliper.

Fig 8: Removing Parking Brake Rear Cable
Courtesy of FORD MOTOR CO.
Separate the parking brake cable and conduit from the knuckle.

Fig 9: Separating Parking Brake Cable And Conduit From Knuckle
Courtesy of FORD MOTOR CO.
Remove the rear brake caliper and support bracket from the knuckle as an assembly. Wire the caliper and support bracket assembly out of the way.

Fig 10: Identifying Rear Brake Caliper And Support Bracket Removing Bolt
Courtesy of FORD MOTOR CO.
Remove the brake disc.

Fig 11: Removing Brake Disc
Courtesy of FORD MOTOR CO.
Remove the rear brake anti-lock sensor and position it aside.

Fig 12: Removing Rear Brake Anti-Lock Sensor
Courtesy of FORD MOTOR CO.
Support the lower suspension arm and bushing with a jack stand.
Remove the nuts and disconnect the stabilizer bar links.
- Discard the nuts.
Fig 13: Identifying Stabilizer Bar Links Disconnecting Nut
Courtesy of FORD MOTOR CO.
Remove and discard the cotter pin and nut.

Fig 14: Removing Cotter Pin And Nut
Courtesy of FORD MOTOR CO.

CAUTION: Do not strike the toe link or the knuckle to disconnect the toe link from the knuckle.

Fig 15: Disconnecting Toe Link From Knuckle

Courtesy of FORD MOTOR CO.

Using the special tool, disconnect the toe link from the knuckle.
Mark the cam bolt position relative to the upper suspension arm and bushing.

Fig 16: Marking Cam Bolt Position Relative To Upper Suspension Arm And Bushing
Courtesy of FORD MOTOR CO.
Disconnect the knuckle from the lower suspension arm and bushing.
1. Remove and discard the nut and bolt.
2. Disconnect the knuckle from the lower suspension arm and bushing.
  
  Fig 17: Disconnecting Knuckle From Lower Suspension Arm And Bushing
  Courtesy of FORD MOTOR CO.

NOTE: Mark the new cam bolt in the same position as the old one for assembly reference before discarding the old bolt.

Disconnect the knuckle from upper suspension arm and bushing.
1. Remove and discard the nut and bolt.
2. Disconnect the knuckle from the upper suspension arm and bushing.
  
  Fig 18: Disconnecting Knuckle From Upper Suspension Arm And Bushing
  Courtesy of FORD MOTOR CO.

CAUTION: The crown on the tool forks must face away from the differential housing. Position the special tool correctly between the CV joint and the differential housing so as not to damage the differential seal.

Fig 19: Separating CV Joint From Differential Side Gear

Courtesy of FORD MOTOR CO.

Using the special tool, exert enough pressure to overcome the circlip and separate the CV joint from the differential side gear.
Install the special tool.

Fig 20: Installing Special Tool
Courtesy of FORD MOTOR CO.
Remove the halfshaft and knuckle assembly from the vehicle.

Fig 21: Removing Halfshaft And Knuckle Assembly From Vehicle
Courtesy of FORD MOTOR CO.
Insert the special tool into the housing bore.

Fig 22: Inserting Special Tool Into Housing Bore
Courtesy of FORD MOTOR CO.
Remove the other halfshaft and knuckle assembly as described in the previous steps.
Support the axle housing with a transmission jack.
Remove the rear insulator bolts.

Fig 23: Removing Rear Insulator Bolts
Courtesy of FORD MOTOR CO.
Remove the front lower insulator bolts and front lower insulator nuts.

Fig 24: Removing Front Lower Insulator Bolts
Courtesy of FORD MOTOR CO.
Remove the pinion nose crossmember nuts.

Fig 25: Removing Pinion Nose Crossmember Nuts
Courtesy of FORD MOTOR CO.

NOTE: Do not loosen the pinion nose crossmember bolt more than specification.

Fig 26: Loosening Pinion Nose Crossmember Bolts

Courtesy of FORD MOTOR CO.

Loosen the pinion nose crossmember bolts 22.23 mm (0.87 in).
Remove the crossmember, the vibration dampener and the front lower insulators as an assembly.

Fig 27: Removing Crossmember, Vibration Dampener And Front Lower Insulators
Courtesy of FORD MOTOR CO.

CAUTION: Do not damage the axle vent hose.

Lower the axle assembly from the vehicle.