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Home >> Ford >> 2006 >> Freestar SE >> Repair and Diagnosis >> External Pages >> Different car >> Section 772 (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 2007 Ford Pickup and 2007 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
Material

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 AND TIRES article.
    2. Fig 1: Stone Shield
    GF0006343Courtesy of FORD MOTOR CO.
  2. Remove the 2 nuts and the stone shield.
    • To install, tighten to 62 Nm (46 lb-ft).
    3. Fig 2: Caliper Pin Bolts
    GF0006344Courtesy 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).
    4. Fig 3: Rear Disc Brake Caliper
    GF0006345Courtesy of FORD MOTOR CO.
    CAUTION: Do not allow the rear disc brake caliper to hang by the brake hose. Provide suitable support or damage to the component may occur.
  4. Position aside the rear disc brake caliper.
    5. Fig 4: Fully Releasing Parking Brake
    GF0006346Courtesy of FORD MOTOR CO.
    NOTE: Make sure the parking brake control is fully released.
  5. Release the tension on the parking brake system.
    • Have an assistant pull the front parking brake cable and conduit to its full range.
    • Insert a suitable retainer.
    6. Fig 5: Parking Brake Cable At Parking Brake Lever
    GF0006347Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  6. Disconnect the parking brake cable at the parking brake lever.
    7. Fig 6: Rear Anti-Lock Brake Sensor Electrical Connector & Clip
    GF0006348Courtesy of FORD MOTOR CO.
  7. Disconnect the rear anti-lock brake sensor electrical connector. Release the harness clips and position the harness aside.
    8. Fig 7: Cable Clamp Bolt
    GF0006349Courtesy of FORD MOTOR CO.
  8. Remove the cable clamp bolt.
    • To install, tighten to 20 Nm (15 lb-ft).
    9. Fig 8: Parking Brake Cable Bracket & Brake Line
    GF0006350Courtesy 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).
    10. Fig 9: Brake Hose Bracket & Bolt
    GF0006351Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  10. Remove the bolt from the brake hose bracket.
    • To install, tighten to 7 Nm (62 lb-in).
    11. Fig 10: Removing Brake Line From Retaining Clip
    GF0003092Courtesy of FORD MOTOR CO.
  11. Remove the brake tube from the brake tube retaining clip.
    12. Fig 11: Brake Hose Junction Block Vent Hose
    GF0006352Courtesy of FORD MOTOR CO.
  12. Remove the vent hose at the brake hose junction block.
    13. Fig 12: Brake Hose Junction Block
    GF0006353Courtesy 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).
  14. Remove the brake tubes from the rear axle housing tie strap (but not from the disc brake calipers) and position it aside.
    15. Fig 13: Securing Axle To Jack
    GF0006354Courtesy of FORD MOTOR CO.
    WARNING: Secure the assembly to the jack. Avoid any obstructions while lowering and raising the jack. Contact with obstructions may cause the assembly to fall off the jack, which may result in serious personal injury.
  15. Use a suitable transmission jack to support the axle.
    16. Fig 14: Shock Absorber Lower Nuts & Bolts
    GF0006355Courtesy of FORD MOTOR CO.
  16. Remove the 2 lower shock absorber nuts and bolts.
    • To install, tighten to 90 Nm (66 lb-ft).
    17. Fig 15: Stabilizer Bar Link Lower End Nuts
    GF0006356Courtesy of FORD MOTOR CO.
  17. Loosen the 2 nuts from both lower ends of the stabilizer bar links.
    • To install, tighten to 103 Nm (76 lb-ft).
    18. Fig 16: Stabilizer Bar
    GF0006357Courtesy of FORD MOTOR CO.
    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).
    19. Fig 17: U-Bolts & Nuts
    GF0006358Courtesy of FORD MOTOR CO.
    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 185 Nm (136 lb-ft).
  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 AND TIRES article.
  23. Make sure the axle is filled to specification.
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