LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2009 >> Flex Limited, FWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 867 (Rear Drive Axle/Differential - Ford 7.5-Inch Ring Gear) >> In-Vehicle Servicing >> Axle Shaft >> Installation

Axle Shaft: Installation

WARNING: This page is about a different car, the 2007 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
  1. Lubricate the lip of the wheel bearing oil seal with grease.
  2. Fig 1: Installing Axle Shaft
    GF0003062Courtesy of FORD MOTOR CO.
    NOTE: Do not damage the wheel bearing oil seal.
  3. Install the 2 axle shafts.
  4. Fig 2: Installing Axle Shaft U-Washer
    GF0003063Courtesy of FORD MOTOR CO.
    NOTE: Do not damage the rubber O-rings in the axle shaft grooves.
  5. Install the U-washers.
    1. Position the 2 U-washers on the button end of the axle shafts.
    2. Pull the axle shafts outward.
  6. Fig 3: Identifying Differential Pinion Shaft Lock Bolt
    GF0003064Courtesy of FORD MOTOR CO.
  7. Install the differential pinion shaft.
    • Align the hole in the differential pinion shaft with the case lock bolt hole.
    • Install a new differential pinion shaft lock bolt.
      • Tighten to 30 Nm (22 lb-ft).
  8. Install the rear brake drums. For additional information, refer to DRUM BRAKE .
  9. NOTE: Make sure the machined surfaces on 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 must be covered when cleaning the machined surface to prevent contamination.
  10. Clean the gasket mating surface of the rear axle and the differential housing cover.
  11. Fig 4: Applying Sealer To Cover
    GF0000820Courtesy of FORD MOTOR CO.
  12. Apply a new continuous bead of sealant of the specified thickness to the differential housing cover.
  13. Fig 5: Identifying Differential Housing Cover Bolts
    GF0003076Courtesy of FORD MOTOR CO.
    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.
  14. Install the differential housing cover and the 10 bolts.
    • Tighten to 45 Nm (33 lb-ft).
  15. Fig 6: Locating Filler Plug (With Fill Specification)
    GF0003077Courtesy of FORD MOTOR CO.
    NOTE: Service refill capacities are determined by filling the rear axle with the specified lubricant to the level shown in the illustration.
  16. Remove the filler plug and fill the rear axle with 2.4L (5 pt) with the specified lubricant and install the fill plug.
    • Tighten to 52 Nm (38 lb-ft).
  17. Install the wheels and tires. For additional information, refer to WHEELS AND TIRES .