Lincoln Aviator, Ford Explorer, Exp Sport, Exp Sport-Trac, Mercury Mountaineer 2000-2005

Axle Shaft, Bearing & Seal

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Removal & Installation



Ford 8.8 Inch Ring Gear Solid Axle
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Raise and support the vehicle.
  4.  
  5. Remove the wheel and tire assembly.
  6.  
  7. Loosen the bolts and drain the lubricant from the rear axle housing.
  8.  
  9. Remove the cover bolts.
  10.  
  11. Remove the differential housing cover.
  12.  
  13. Remove the rear brake disc or brake drum and shoes.
    WARNING
    Turning the differential case or an axle shaft with the differential pinion shaft removed will cause the differential pinion gears to fall out of the assembly and damage the components.

  14.  
  15. Remove the differential pinion shaft lock bolt.
  16.  
  17. Remove the differential pinion shaft.
    WARNING
    Do not damage the rubber O-ring in the U-washer groove.

  18.  
  19. Push the axle shaft inboard.
  20.  
  21. Remove the U-washer.
  22.  
  23. Install the differential pinion shaft.
  24.  
  25. Install the differential pinion shaft lock bolt finger-tight.
    WARNING
    Do not damage the wheel bearing oil seal.

  26.  
  27. Remove the axle shaft.
    NOTE
    If the wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign material.


    NOTE
    If only a new seal needs to be installed, use care to avoid damaging the seal bore.

  28.  
  29. Using a suitable seal remover, remove the axle shaft oil seal. Discard the oil seal.
  30.  
  31. Inspect the rear wheel bearing and axle shaft for wear or damage.
  32.  
  33. If necessary, using the special tools, remove the rear wheel bearing.

    Click image to see an enlarged view

    Fig. Rear wheel bearing and seal removal-8.8 inch solid axle

  34.  

To install:

Click image to see an enlarged view

Fig. Rear wheel bearing installation-8.8 inch solid axle



Click image to see an enlarged view

Fig. Rear axle seal installation-8.8 inch solid axle

  1. Lubricate the new rear wheel bearing.
    1. For limited slip rear axles, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.
    2.  
    3. For conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A.
    4.  

  2.  
  3. Using a bearing driver, install the rear wheel bearing.
  4.  
  5. Lubricate the lip of the new wheel bearing oil seal. Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.
  6.  
  7. Using a seal driver, install the wheel bearing oil seal.
  8.  
  9. 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.
    WARNING
    Turning the differential case or an axle shaft with the differential pinion shaft removed will cause the differential pinion gears to fall out of the assembly and damage the components.

  10.  
  11. Remove the differential pinion shaft lock bolt.
  12.  
  13. Remove the differential pinion shaft.
    WARNING
    Do not damage the wheel bearing oil seal.

  14.  
  15. Install the axle shaft.
    WARNING
    Do not damage the rubber O-ring in the U-washer groove.

  16.  
  17. Position the U-washer on the button end of the axle shaft.
  18.  
  19. Pull the axle shaft outward.
    WARNING
    If a new pinion shaft lock bolt is unavailable, coat the threads with Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5.

  20.  
  21. Align the hole in the differential pinion shaft with the differential pinion shaft lock bolt hole.
  22.  
  23. Install a new differential pinion shaft lock bolt. Torque to 22 ft. lbs. (30 Nm).
  24.  
  25. Install the rear brake disc or shoes and drum.
    NOTE
    The machined surfaces on the differential housing and the differential housing cover must be clean and free of oil before applying the silicone sealant. Cover the inside of the rear axle prior to cleaning the machined surface to prevent contamination.

  26.  
  27. Clean the cover gasket mating surfaces.
    NOTE
    Install the differential housing cover within 15 minutes of applying the silicone, or it will be necessary to apply new sealant.

  28.  
  29. Apply a continuous bead of sealant to the differential housing cover. Use Clear Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specification ESB-M4G92-A.
    NOTE
    If possible, allow one hour before filling the axle with lubricant to allow the silicone sealant to cure.

  30.  
  31. Position the differential housing cover. Install the bolts. Torque to 33 ft. lbs. (45 Nm).
  32.  
  33. Fill the rear axle housing with the specified lubricant type and quantity.
    NOTE
    For Traction-Lok®axles, first fill the rear axle with 118 ml (4 oz) of Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A.


    NOTE
    Service refill capacities are determined by filling the rear axle to the level shown.

  34.  
  35. Fill the rear axle with lubricant and install the fill plug.
    1. For conventional axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A.
    2.  
    3. For Traction-Lok®axles, use SAE 75W-140 Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.
    4.  

  36.  
  37. Install the wheel and tire assembly.
  38.  

  1. Before servicing the vehicle, refer to the -Precautions- section.
  2.  
  3. Raise and support the vehicle.
  4.  
  5. Remove the wheel and tire assembly.
  6.  
  7. Loosen the bolts and drain the lubricant from the rear axle housing.
  8.  
  9. Remove the cover bolts.
  10.  
  11. Remove the differential housing cover.
  12.  
  13. Remove the rear brake disc or brake drum and shoes.
    WARNING
    Turning the differential case or an axle shaft with the differential pinion shaft removed will cause the differential pinion gears to fall out of the assembly and damage the components.

  14.  
  15. Remove the differential pinion shaft lock bolt.
  16.  
  17. Remove the differential pinion shaft.
    WARNING
    Do not damage the rubber O-ring in the U-washer groove.

  18.  
  19. Push the axle shaft inboard.
  20.  
  21. Remove the U-washer.
  22.  
  23. Install the differential pinion shaft.
  24.  
  25. Install the differential pinion shaft lock bolt finger-tight.
    WARNING
    Do not damage the wheel bearing oil seal.

  26.  
  27. Remove the axle shaft.
    NOTE
    If the wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign material.


    NOTE
    If only a new seal needs to be installed, use care to avoid damaging the seal bore.

  28.  
  29. Using a suitable seal remover, remove the axle shaft oil seal. Discard the oil seal.
  30.  
  31. Inspect the rear wheel bearing and axle shaft for wear or damage.
  32.  
  33. If necessary, using the special tools, remove the rear wheel bearing.

    Click image to see an enlarged view

    Fig. Rear wheel bearing and seal removal-8.8 inch solid axle

  34.  

To install:

Click image to see an enlarged view

Fig. Rear wheel bearing installation-8.8 inch solid axle



Click image to see an enlarged view

Fig. Rear axle seal installation-8.8 inch solid axle

  1. Lubricate the new rear wheel bearing.
    1. For limited slip rear axles, use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.
    2.  
    3. For conventional rear axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A.
    4.  

  2.  
  3. Using a bearing driver, install the rear wheel bearing.
  4.  
  5. Lubricate the lip of the new wheel bearing oil seal. Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.
  6.  
  7. Using a seal driver, install the wheel bearing oil seal.
  8.  
  9. 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.
    WARNING
    Turning the differential case or an axle shaft with the differential pinion shaft removed will cause the differential pinion gears to fall out of the assembly and damage the components.

  10.  
  11. Remove the differential pinion shaft lock bolt.
  12.  
  13. Remove the differential pinion shaft.
    WARNING
    Do not damage the wheel bearing oil seal.

  14.  
  15. Install the axle shaft.
    WARNING
    Do not damage the rubber O-ring in the U-washer groove.

  16.  
  17. Position the U-washer on the button end of the axle shaft.
  18.  
  19. Pull the axle shaft outward.
    WARNING
    If a new pinion shaft lock bolt is unavailable, coat the threads with Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5.

  20.  
  21. Align the hole in the differential pinion shaft with the differential pinion shaft lock bolt hole.
  22.  
  23. Install a new differential pinion shaft lock bolt. Torque to 22 ft. lbs. (30 Nm).
  24.  
  25. Install the rear brake disc or shoes and drum.
    NOTE
    The machined surfaces on the differential housing and the differential housing cover must be clean and free of oil before applying the silicone sealant. Cover the inside of the rear axle prior to cleaning the machined surface to prevent contamination.

  26.  
  27. Clean the cover gasket mating surfaces.
    NOTE
    Install the differential housing cover within 15 minutes of applying the silicone, or it will be necessary to apply new sealant.

  28.  
  29. Apply a continuous bead of sealant to the differential housing cover. Use Clear Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specification ESB-M4G92-A.
    NOTE
    If possible, allow one hour before filling the axle with lubricant to allow the silicone sealant to cure.

  30.  
  31. Position the differential housing cover. Install the bolts. Torque to 33 ft. lbs. (45 Nm).
  32.  
  33. Fill the rear axle housing with the specified lubricant type and quantity.
    NOTE
    For Traction-Lok®axles, first fill the rear axle with 118 ml (4 oz) of Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A.


    NOTE
    Service refill capacities are determined by filling the rear axle to the level shown.

  34.  
  35. Fill the rear axle with lubricant and install the fill plug.
    1. For conventional axles, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A.
    2.  
    3. For Traction-Lok®axles, use SAE 75W-140 Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.
    4.  

  36.  
  37. Install the wheel and tire assembly.
  38.  

Solid Axle
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the axle housing fluid.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Rear wheel
     
    Brake drum
     
    Wheel speed sensor, if equipped
     
    Axle housing cover
     
    Bearing retainer nuts
     
    Axle shaft and bearing
     
    Axle shaft inner oil seal
     

  6.  
  7. If equipped with ABS, grind a flat spot on the wheel speed sensor tone ring, then split the ring with a chisel.
  8.  
  9. Press the wheel bearing off the axle shaft.
  10.  
  11. Remove the bearing retainer and the outer oil seal.
  12.  

To install:

  1. Install or connect the following:

    Outer oil seal to the bearing retainer
     
    Bearing retainer to the axle shaft
     
    Bearing and retainer ring pressed onto the axle shaft
     
    Wheel speed sensor tone ring pressed onto the axle shaft, if equipped
     
    Axle shaft inner oil seal
     
    Axle shaft and bearing
     
    Bearing retainer nuts. Tighten them to 17 ft. lbs. (23 Nm).
     
    Wheel speed sensor, if equipped
     
    Brake drum
     
    Rear wheel
     
    Negative battery cable
     

  2.  
  3. Fill the rear differential to the correct level.
  4.  

 
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