Axle Shaft: Installation

WARNING: This page is about a different car, the 2003 Mercury Marauder, 2003 Mercury Grand Marquis, and 2003 Ford Crown Victoria. However, it is still accessible from the selected car via links, so may be relevant.

Place rear brake anti-lock sensor indicator on a bearing plate and insert the axle shaft through the indicator.

Fig 1: Placing Rear Brake Anti-Lock Sensor Indicator On A Bearing Plate
Courtesy of FORD MOTOR CO.
Press the axle shaft through the rear brake anti-lock sensor indicator until it bottoms out on the axle flange.

Fig 2: Pressing Axle Shaft Through Rear Brake Anti-Lock Sensor Indicator
Courtesy of FORD MOTOR CO.
Lubricate the lip of the wheel bearing oil seal.
- Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.
  
  Fig 3: Lubricating Lip Of Wheel Bearing Oil Seal
  Courtesy of FORD MOTOR CO.

CAUTION: Once the differential pinion shaft has been removed, turning the differential case or an axle shaft can cause the differential pinion gears to fall out of the assembly. This can result in chipped or damaged components.

Fig 4: Removing Differential Pinion Shaft

Courtesy of FORD MOTOR CO.

Remove the differential pinion shaft.
1. Remove the differential pinion shaft lock bolt.
2. Remove the differential pinion shaft.

CAUTION: Do not damage the wheel bearing oil seal.

Fig 5: Installing Axle Shaft

Courtesy of FORD MOTOR CO.

Install the axle shaft.

CAUTION: Do not damage the rubber O-ring in the U-washer groove.

Install the U-washer.
1. Position the U-washer on the button end of the axle shaft.
2. Pull the axle shaft outward to seat the U-washer in the side gear.
  
  Fig 6: Installing U-Washer
  Courtesy of FORD MOTOR CO.
Install the differential pinion shaft.
1. Align the hole in the differential pinion shaft with the lock bolt hole.
2. Install the differential pinion shaft lock bolt.
  
  Fig 7: Installing Differential Pinion Shaft Lock
  Courtesy of FORD MOTOR CO.
Install the brake disc and the brake caliper. For additional information, refer to DISC .

Fig 8: Identifying Brake Disc And Brake Caliper
Courtesy of FORD MOTOR CO.
Install the rear brake anti-lock sensor. For additional information, refer to ANTI-LOCK CONTROL - TRACTION CONTROL .

Fig 9: Installing Rear Brake Anti-Lock Sensor
Courtesy of FORD MOTOR CO.
Install the differential housing cover and fill the differential housing with the specified lubricant. For additional information, refer to DIFFERENTIAL HOUSING COVER in this section.
1. Position the cover.
2. Install the bolts.
  
  Fig 10: Installing Differential Housing Cover
  Courtesy of FORD MOTOR CO.

WARNING: Always remove any corrosion, dirt or foreign material that may be present on the mounting surfaces of the wheel or the surface of the wheel hub or rear brake disc that contacts the wheel. Installing wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the wheel nut to loosen and the wheel to come off while the vehicle is in motion, causing loss of control.

Clean the wheel hub and mounting surfaces.
Install the wheel and tire assembly. For additional information, refer to WHEELS AND TIRES .

Fig 11: Installing Wheel And Tire Assembly
Courtesy of FORD MOTOR CO.
Install the center cap.

NOTE: If equipped with air suspension, reactivate the system by turning the air suspension switch on.

Lower the vehicle.