Axle Assembly - Removal and Installation

Special Service Tools / General Equipment

Transmission Jack

Materials

Removal

1. 1
   Remove the rear axle shafts.
   Refer to: Rear Axle Shaft (205-05 Rear Axle Shafts, Removal and Installation).
2. 2
   Remove and discard the driveshaft flange-to-rear differential bolts and washer assemblies.
   Torque: 26 lb-ft (35 N·m)

   

3. 3
   
   Disconnect the driveshaft.
   

   1. Mark the driveshaft CV joint and the RDU (rear drive unit) flange with an index mark.

   2. Separate the driveshaft CV joint from the RDU flange.

   3. Position and support the driveshaft aside.

   

4. 4
   Disconnect the ATC connector.

   

5. 5
   Disconnect the RDU vent tube.

   

6. 6
   Position and secure a transmission jack under the RDU.
   Use common shop equipment: transmission jack.

   

7. 7
   Remove the rear RDU mounting bolts.
   Torque: 66 lb-ft (90 N·m)

   

8. 8
   Remove the front RDU mounting bolts and, using the transmission jack, remove the RDU.
   Use common shop equipment: transmission jack.
   Torque: 66 lb-ft (90 N·m)

   

9. 9
   When installing a new RDU.
   Remove the RDU mounting bracket bolts and mounting brackets.
   Torque: 66 lb-ft (90 N·m)

   

10. 10
    When installing a new RDU.
    Remove the RDU mounting bracket bolts and mounting brackets.
    Torque: 66 lb-ft (90 N·m)

    

Installation

1. 1

   NOTICE: When replacing the axle assembly, the 4X4 control module must be reconfigured with the new Active Torque Coupling (ATC) bar code information. If the new bar code information does not match the existing 4X4 control module information, transmission damage or handling concerns may occur.

   After installing a new RDU, reconfigure the Active Torque Coupling (ATC).
   Refer to: All Wheel Drive Systems (308-07A All Wheel Drive Systems, Diagnosis and Testing).
2. 2
   To install, reverse the removal procedure.
3. 3
   If empty, fill the rear axle with 0.6 L Rear Axle Lubricant. If the fluid level is low, fill to 3-5 mm (0.118-0.196 in) below the bottom of the fill hole and install the fill plug.
   Material: Motorcraft® SAE 80W-90 Premium Rear Axle Lubricant / XY-80W90-QL (WSP-M2C197-A)
   Torque: 21 lb-ft (29 N·m)