Rear Drive Axle/Differential - Ford 7.5-Inch Ring Gear

Axle Shaft













Removal

1. With the vehicle in NEUTRAL, position it on a hoist.

2. Remove the wheel and tire.

3. Remove the differential housing cover.

1. Remove the 10 differential housing cover bolts and drain the lubricant from the rear axle housing.

2. Remove the differential housing cover.





4. Remove the rear brake drums.

5. Remove the differential pinion shaft.

1. Remove and discard the differential pinion shaft lock bolt.

2. Remove the differential pinion shaft.





6. Remove the U-washers.

1. Push the axle shafts inboard.

2. Remove the U-washers.





7. Remove the 2 axle shafts.





Installation

1. Lubricate the lip of the wheel bearing oil seal with grease.

2. NOTE: Do not damage the wheel bearing oil seal.

Install the 2 axle shafts.





3. NOTE: Do not damage the rubber O-rings in the axle shaft grooves.

Install the U-washers.

1. Position the 2 U-washers on the button end of the axle shafts.

2. Pull the axle shafts outward.





4. 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).





5. Install the rear brake drums.

6. 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.

Clean the gasket mating surface of the rear axle and the differential housing cover.

7. Apply a new continuous bead of sealant of the specified thickness to the differential housing cover.





8. 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.

Install the differential housing cover and the 10 bolts.

- Tighten to 45 Nm (33 lb-ft).





9. NOTE: Service refill capacities are determined by filling the rear axle with the specified lubricant to the level shown in the illustration.

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).





10. Install the wheels and tires.