Axle Vent Replacement

REMOVAL
1. Raise vehicle on hoist.





2. Support rear axle housing and remove rear axle differential rear insulator-to-crossmember retaining nuts.





3. Position drain pan under rear axle housing. Remove fill plug with 3/8-inch flex handle and remove axle housing cover to housing retaining bolts.
4. Remove rear axle housing cover.





5. Remove lubricant deflector using 1/8-inch Allen wrench.





6. Pry out rear axle housing vent with screwdriver.





INSTALLATION
1. Install rear axle housing vent as shown. Notch in rear axle housing vent must be aligned with nub in axle housing cover.





2. Seat rear axle housing vent using 9/32-inch deep well socket or similar tool to drive against rear axle housing vent lip. Do not hammer on end of vent tube.

Deflector Installation:

Deflector Gap:

3. Install lubricant deflector using 1/8-inch Allen wrench. A gap of 5.08-6.35 mm (0.200-0.250 inch) must exist between deflector and back face of axle housing cover.

CAUTION: If shield gap is not 5.08-6.35 mm (0.200-0.250 inch) it will cause vent leak and axle overheating.





4. Inspect rear axle hose for cracks and restrictions. Replace as required. Install rear axle hose.





5. Clean sealing surfaces and groove in axle housing cover.

NOTE: Make sure rear axle housing vent and brake and fuel line tubing are not plugged. When installing axle housing cover, insert open end of brake and fuel line tubing into hole in crossmember.





6. Apply continuous bead of Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specifications ESE-M4G195-A and ESB-M4G92-A to groove in axle housing cover.

CAUTION: Make sure machined surfaces on both axle housing cover and rear axle housing are clean before installing new silicone rubber. Inside of rear axle housing must be covered when cleaning machined surface to prevent rear axle housing contamination.

NOTE: Axle housing cover assembly must be installed within 15 minutes of application of silicone rubber or new silicone rubber must be applied.
7. Position axle housing cover retaining bolts (place service identification tag in the 12 o'clock position). Tighten to 27-37 Nm (20-27 ft. lbs.).

CAUTION: Tighten axle housing cover bolts in a crosswise pattern to prevent distortion of axle housing cover.

8. Install rear axle differential rear insulator to crossmember nuts. Tighten to 108-136 Nm (80-100 ft. lbs.).
9. Fill rear axle housing with SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or -KL or equivalent meeting Ford specification WSP-M2C197-A to 6 mm (0.250 inch) below filler hole. For Traction-Lok(r) axles, add 118 ml (4 ounces) of Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A.





10. Install filler plug. Tighten to 28-40 Nm (21-29 ft. lbs.).