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Home >> Ford >> 2009 >> Flex Limited, FWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1518 (Rear Drive Axle, Differential - Ford 8.8-Inch Ring Gear) >> In-Vehicle Servicing >> Axle Shaft >> Installation

Axle Shaft: Installation

WARNING: This page is about a different car, the 2009 Mercury Grand Marquis and 2009 Ford Crown Victoria. However, it is still accessible from the selected car via links, so may be relevant.
  1. Using long-life grease, lubricate the lip of the wheel bearing oil seal.
    2. Fig 1: Wheel Bearing Oil Seal
    GF0013937Courtesy of FORD MOTOR CO.
    CAUTION: Once the differential pinion shaft has been removed, turning the differential case or an axle shaft can cause the differential pinion gears to fall out of the assembly. This may result in chipped or damaged components.
  2. Remove the differential pinion shaft.
    1. Remove the differential pinion shaft lock bolt and discard.
    2. Remove the differential pinion shaft.
    3. Fig 2: Differential Pinion Shaft & Lock Bolt
    GF0013938Courtesy of FORD MOTOR CO.
    NOTE: Do not damage the wheel bearing oil seal.
  3. Install the axle shaft.
    4. Fig 3: Axle Shaft
    GF0013939Courtesy of FORD MOTOR CO.
    NOTE: Do not damage the rubber O-ring in the axle shaft U-washer groove.
  4. Install the axle shaft U-washer.
    1. Position the U-washer on the button end of the axle shaft.
    2. Pull the axle shaft outward to seat the U-washer in the side gear.
    5. Fig 4: Identifying U-Washer
    GF0013940Courtesy of FORD MOTOR CO.
  5. Install the differential pinion shaft.
    1. Align the hole in the differential pinion shaft with the lock bolt hole.
    2. Install a new differential pinion shaft lock bolt.
      • Tighten to 30 Nm (22 lb-ft).
    6. Fig 5: Differential Pinion Shaft & Lock Bolt
    GF0013941Courtesy of FORD MOTOR CO.
  6. Install the differential housing cover. For additional information, refer to Differential Housing Cover .
  7. Install the rear brake anti-lock sensor and bolt.
    • Tighten to 7 Nm (62 lb-in).
  8. Install the rear brake caliper and the brake disc. For additional information, refer to REAR DISC BRAKE article.
    9. WARNING: If the vehicle is equipped with a fire suppression system, repower the system. For important safety warnings and procedures, refer to FIRE SUPPRESSION SYSTEM article. Failure to follow these instructions may result in serious personal injury.
  9. Repower the system.
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