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Home >> Ford >> 2006 >> Expedition RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 517 (Rear Drive Axle/Differential - DANA 80 -- F350 Super Duty) >> Removal And Installation >> Axle Assembly

Axle Assembly

WARNING: This page is about a different car, the 2006 Ford Pickup and 2006 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
MATERIAL SPECIFICATION

Item Specification
SAE 75W-90 Premium Synthetic Transaxle Lubricant XT-75W90-QGT GL-5
  1. Remove the wheels and tires. For additional information, refer to WHEELS & TIRES .
  2. Remove the 2 nuts and the stone shield.
    • To install, tighten to 62 Nm (46 lb-ft).
      Fig 1: Locating Stone Shield
      G04643611Courtesy of FORD MOTOR CO.
  3. Remove the 2 caliper pin bolts.
    • To install, tighten F-250/350 to 36 Nm (27 lb-ft). Tighten F-450/550 to 55 Nm (41 lb-ft).
      Fig 2: Locating Caliper Pin Bolts
      G04643612Courtesy of FORD MOTOR CO.
    4. CAUTION: Do not allow the rear disc brake caliper to hang by the brake hose. Provide suitable support.
    Fig 3: Locating Rear Disc Brake Caliper
    G04643613Courtesy of FORD MOTOR CO.
  4. Position aside the rear disc brake caliper.
    5. NOTE: Make sure the parking brake control is fully released.
  5. Release the tension on the parking brake system.
    1. Have an assistant pull the front parking brake cable and conduit to its full range.
    2. Insert a suitable retainer.
      Fig 4: Pulling Front Parking Brake Cable
      G04643614Courtesy of FORD MOTOR CO.
    6. NOTE: LH shown, RH similar.
    Fig 5: Disconnecting Parking Brake Cable
    G04643615Courtesy of FORD MOTOR CO.
  6. Disconnect the parking brake cable at the parking brake lever.
  7. Disconnect the rear anti-lock brake sensor electrical connector. Release the harness clips and position the harness aside.
    Fig 6: Locating Rear Anti-Lock Brake Sensor Electrical Connector
    G04643616Courtesy of FORD MOTOR CO.
  8. Remove the cable clamp bolt.
    • To install, tighten to 20 Nm (15 lb-ft).
      Fig 7: Locating Cable Clamp Bolt
      G04643617Courtesy of FORD MOTOR CO.
  9. Unclip the brake line and remove the retainer from the parking brake cable bracket and position the cable aside.
    • To install, tighten to 18 Nm (13 lb-ft).
      Fig 8: Locating Parking Brake Cable Bracket
      G04643618Courtesy of FORD MOTOR CO.
    10. NOTE: LH shown, RH similar.
  10. Remove the bolt from the brake hose bracket.
    • To install, tighten to 7 Nm (62 lb-in).
      Fig 9: Locating Brake Hose Bracket Bolt
      G04643619Courtesy of FORD MOTOR CO.
  11. Remove the brake tube from the brake tube retaining clip.
    Fig 10: Removing Brake Tube
    G04643620Courtesy of FORD MOTOR CO.
  12. Remove the vent hose at the brake hose junction block.
    Fig 11: Removing Vent Hose
    G04643621Courtesy of FORD MOTOR CO.
  13. Remove the brake junction block from the rear axle housing and position it aside.
    • To install, tighten to 17 Nm (13 lb-ft).
      Fig 12: Locating Brake Junction Block
      G04643622Courtesy of FORD MOTOR CO.
  14. Remove the brake tubes from the rear axle housing tie strap (but not from the disc brake calipers) and position it aside.
    15. WARNING: Strap the axle securely to the jack.
    Fig 13: Locating Jack
    G04643623Courtesy of FORD MOTOR CO.
  15. Use a suitable transmission jack to support the axle.
  16. Remove the 2 lower shock absorber nuts and bolts.
    • To install, tighten to 90 Nm (66 lb-ft).
      Fig 14: Locating Lower Shock Absorber Nuts And Bolts
      G04643624Courtesy of FORD MOTOR CO.
  17. Loosen the 2 nuts from both lower ends of the stabilizer bar links.
    • To install, tighten to 70 Nm (52 lb-ft).
      Fig 15: Locating Bar Links Bolt
      G04643625Courtesy of FORD MOTOR CO.
    18. NOTE: When lowering or raising the differential housing, position the sway bar forward to clear the front of the differential housing.
  18. Remove the 4 nuts from both stabilizer bar retainer-to-axle brackets and remove the stabilizer bar retainers, stabilizer bar mounting brackets and U-bolts. Let the stabilizer bar hang from the links.
    • To install, tighten to 40 Nm (30 lb-ft).
      Fig 16: Locating Stabilizer Bar Mounting Brackets And U-Bolts
      G04643626Courtesy of FORD MOTOR CO.
    19. NOTE: Once the rear spring plate nuts and bolts are removed, new rear spring plate nuts and bolts must be installed.
  19. Remove the rear spring plate U-bolts and nuts.
    • To install, tighten to 200 Nm (148 lb-ft).
      Fig 17: Locating Rear Spring Plate U-Bolts And Nuts
      G04643627Courtesy of FORD MOTOR CO.
  20. Lower the axle from the vehicle.
  21. To install, reverse the removal procedure.
  22. Install the wheels and tires. For additional information, refer to WHEELS & TIRES .
  23. Make sure the axle is filled to specification.
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