Installation
1. Transfer all components from old rear axle housing to new rear axle housing and make the necessary adjustments to backlash and preload. install rear axle housing vent.
2. Install new rear wheel bearings into new rear axle housing using Axle Tube Bearing Replacer T78P-1225-A.
3. Install inner wheel bearing oil seal using Axle Tube Seal Replacer T78P-1177-A. Apply Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B between the lips of the inner wheel bearing oil seal.
4. Position new rear axle housing under vehicle and raise rear axle housing with a hoist or jack. Connect the rear suspension arm and bushings to their mounting brackets on rear axle housing. (Do not tighten bolts and nuts at this time.)
5. Position rear springs in upper and lower seats with rear spring center mounting insulator between upper end of rear spring and frame seat.
6. Raise rear axle housing into position.
7. Connect rear suspension arm and bushings to the vehicle. Install bolts and retaining nuts and tighten to 140-180 Nm (103-133 ft. lbs.). Tighten rear suspension arm and bushing to axle retaining bolts to 140-180 Nm (103-133 ft. lbs.).
8. Position brake lines on the rear axle housing and secure with retaining clips. Position and secure brake junction block to the housing cast boss. Tighten to 14-24 Nm (10-17 ft. lbs.).
9. Install rear disc brake caliper anchor plates on axle housing flanges (no gaskets required). Tighten nuts and bolts to 27-40 Nm (20-29 ft. lbs.).
10. Install RH and LH disc brake adapter brackets, bolts and J-nuts. Tighten bolts to 27-54 Nm (20-39 ft. lbs.).
11. Connect rear shock absorber lower studs to the mounting bracket on the rear axle housing. Install the retaining nuts and tighten to 70-115 Nm (52-85 ft. lbs.).
12. Connect driveshaft to rear axle universal joint flange. Install retaining bolts. Tighten to 95-130 Nm (70-95 ft. lbs.).
13. Slide axle shafts into the rear axle housing until the splines enter the differential side gear.
CAUTION: Do not damage inner wheel bearing oil seal or rear brake anti-lock sensor indicator.
14. Push axle shafts at the flange inward, and install the U-washer at the end of each shaft spline. Pull shafts outboard until each U-washer enters the recess in the differential side gears.
Rear Axle Removal:
15. Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1to differential pinion shaft lock pin and install differential pinion shaft and differential pinion shaft lock pin. Tighten to 20-40 Nm (15-30 ft. lbs.).
16. Install rear disc brake rotors and rear disc brake calipers.
17. Install rear brake anti-lock sensor. Tighten retaining bolt to 5-7 Nm (44-62 inch lbs.).
18. Install wheels and tires. Tighten lug nuts to 115-142 Nm (85-105 ft. lbs.).
19. Install axle housing cover using Silicone Rubber D6AZ-19562-AA or -BA or equivalent meeting Ford specification ESB-M4G92A or ESE-M46195-A and tighten axle housing cover bolts to 38-52 Nm (28-38 ft. lbs.).
CAUTION: Make sure machined surfaces of both axle housing cover and rear axle housing are free of old gasket material before applying new silicone sealant. Inside of axle must be covered when cleaning the machined surface to prevent axle contamination. Tighten axle housing cover bolts in a crosswise pattern to prevent distortion of axle housing cover.
NOTE: Axle housing cover must be installed within 15 minutes of application of sealer or new sealer must be applied.
20. Fill axle with Premium Rear Axle Lubricant XY-80W90-QL or -KL or equivalent meeting Ford specification WSP-M2C197-A. Add 118 ml (4 oz.) of Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A until fluid level is within 6-14 mm (1/4-9/16 inch) below bottom fill hole. Be sure the rear axle housing is in operating position. Install filler plug. Tighten to 20-40 Nm (15-30 ft. lbs.).
CAUTION: Overfilling axle can cause rear axle housing vent and seal leakage.
21. Make sure rear axle housing vent is not plugged with debris.
22. Road test vehicle.