Removal

NOTE: Whenever replacing rear axle lubricant, use 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.

CAUTION:
Do not begin this removal procedure unless the following new parts are available:
- Two new CV joint stub driveshaft bearing retainer circlips.
- Two new inboard CV joint stub shaft pilot bearing housing seals.
Once removed, these parts must not be reused during assembly. Their torque holding ability or sealing capacity is diminished during removal.

1. Raise vehicle on a frame contact hoist.

CAUTION: A frame contact hoist must be used to avoid damage to the halfshafts and/or halfshaft boots.

2. Remove both rear wheel and tire assemblies.

CAUTION: Some vehicles are equipped with directional tires. Always make sure tires are installed in their original positions.





3. On vehicles equipped with anti-lock brakes (ABS) remove retaining bolt and RH and LH rear brake anti-lock sensor.

CAUTION: Damage to the rear brake anti-lock sensors may occur if they are not removed before removing halfshafts.





4. Using needle-nose pliers or equivalent, slide parking brake cable adjusting clip downward until parking brake rear cable and conduit (2A635) is released.





5. Remove parking brake rear cable and conduit from RH rear disc brake caliper.
6. Remove upper and lower caliper disc brake caliper locating pins from rear disc brake caliper.
7. Remove rear disc brake caliper from rear disc brake rotor.

CAUTION: To prevent damage, do not stretch, twist or kink brake hose assembly.

Brake Caliper:

8. Carefully wire rear disc brake caliper to brake junction bracket as shown.





9. Remove pushnuts and rear disc brake rotor.





10. Remove RH rear suspension arm and bushing nut and bolt.





11. Wire rear suspension arm and bushing so it does not interfere with or damage rear axle CV joint boot when halfshaft is removed.





12. Using paint marker, mark position of the rear suspension arm and bushing in relation to rear wheel knuckle with rear suspension arm and bushing in relaxed position.

CAUTION: Failure to mark this position will cause bushing "wind-up" on assembly and incorrect ride height which will cause misalignment and premature tire wear.

NOTE: When rear suspension arm and bushing bolt is removed from rear wheel knuckle, rear suspension arm and bushing will return to the relaxed position.





13. Remove RH rear suspension arm and bushing-to-knuckle retaining bolts and nuts.





14. Remove RH halfshaft (inboard CV joint) from rear axle housing using CV Joint Remover T89P-3514-A. Push tool inboard (toward rear axle housing).

CAUTION: Take extreme care not to damage differential oil seal, case, CV joint boot or axle. Differential oil seals must be replaced when halfshaft (CV joint) has been removed.





15. Remove halfshaft and rear wheel knuckle assembly from vehicle.





16. Insert Differential Plug T89P-4850-B into rear axle housing to prevent lubricant loss.





17. Mark driveshaft in relation to rear axle universal joint flange. Remove driveshaft retaining bolts.





18. Slide driveshaft forward and rest on driveshaft center bridge support reinforcement.





19. With a transmission jack supporting the rear axle housing, remove rear axle differential rear insulator retaining nuts.





20. Remove rear axle differential rear insulator from axle housing cover.





21. Remove axle front retaining bolts, nuts, bushings and washers.





22. Remove LH halfshaft (inboard CV joint) from rear axle housing using CV Joint Remover T89P-3514-A. Push tool inboard (toward rear axle housing).

CAUTION: Do not damage CV joint boot.

NOTE: Inboard CV joint stub shaft pilot bearing housing seal must be replaced whenever halfshaft (CV joint) has been removed from the rear axle housing.





23. Partially lower rear axle housing. While lowering rear axle housing, move to the right and disengage rear axle housing from LH inboard CV joint stub shaft.
24. Install Differential Plug T89P-4850-B in LH side of rear axle housing and lower rear axle housing from vehicle.