Ford 5L1Z-3B436-AA Joint And Stub Shaft Assembly

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First of all, to remove the rear axle assembly, turn off the air suspension system if equipped. Loosen the rear wheel lug nuts, lift the rear of the vehicle securely with jack stands, and block the front wheels. Disconnect the rear axle brake lines, vent tube, and brake hose. For truck models, position a floor jack under the differential case, disconnect the shock absorbers, and remove the spring U-bolt nuts, U-bolts, and spring plate. On 4WD models, remove the rear spring spacers while lowering the axle. For Expedition and Navigator models, remove the stabilizer bar brackets, lower the stabilizer bar, disconnect the air suspension system height sensor, and support the rear axle differential case with a floor jack. Disconnect the rear axle track bar, remove the rubber jounce bumper, and disconnect suspension arms and shock absorbers. Lower the axle assembly to the floor.

To remove and install front driveaxles on 2004 and earlier models, turn off air suspension (if equipped), loosen lug nuts, raise vehicle, remove wheel, cotter pin, nut lock, and hub nut. Remove driveaxle flange bolts, steering knuckle, and driveaxle assembly. For installation, follow reverse order, tighten hub nut and CV joint flange bolts, and use new cotter pin. Reactivate air suspension if applicable. On 2005 and later models, remove hub dust cap and driveaxle nut. Loosen lug nuts, raise front of vehicle, support with jackstands, disconnect vacuum tube(s), remove IWE retainer bolts, and disconnect tie-rod end and upper ball joint. Pull steering knuckle outward while pushing inward on driveaxle, use special tool to pull inner driveaxle CV joint away from differential. For rear driveaxles on 2003 and later Expedition/Navigator models, block front wheels, loosen lug nuts, raise rear of vehicle, remove wheel. Depress brake pedal, unscrew driveaxle/hub nut, remove brake disc, suspend brake caliper, remove parking brake cable bolt, cover stabilizer bar link stud threads, detach lower control arm and toe link from rear knuckle. Use puller tool to push driveaxle out of hub, raise lower end of knuckle outward, drive inner end of driveaxle out of differential. For installation, pry off old spring clip, replace it, apply grease, insert splined end of inner CV joint into differential, ensure spring clip locks in place. Apply grease to outer CV joint splines, insert outer end of driveaxle into hub, connect lower control arm and toe link to knuckle, tighten fasteners. Install new driveaxle/hub nut, tighten securely, install parking brake cable, brake disc, and caliper. Have assistant push brake pedal, tighten driveaxle/hub nut, reinstall wheel and lug nuts, lower vehicle, tighten lug nuts.

The axle identification tag is usually located on the differential cover or the inner end of the right axle tube.

Swing the knuckle/hub assembly out (away from the vehicle) until the end of the driveaxle is free of the hub.

After removing the lock bolt, you rotate the differential case 180-degrees and slide the pinion shaft out of the case until the stepped part of the shaft contacts the ring gear.

An optional locking limited-slip rear axle allows for normal operation until one wheel loses traction, at which point it equalizes the rotation speed of the axleshaft driving the wheel with traction.

Tighten the caliper mounting bolts to the specified torque.

After supporting the driveaxles, the front crossmember needs to be removed.

Follow the reverse of the removal process.

The notched end of the pinion shaft should be slid out of the differential case as far as it will go.

For rear driveaxle removal on these models, block the front wheels, loosen the wheel lug nuts, raise the rear of the vehicle with jackstands, and remove the wheel.

The differential is offset to the left, requiring a longer axleshaft on the right side to maintain equal lengths.

Once all attachments are disconnected from the axle housing, you should carefully lower the axle assembly to the floor.

Remove the front carrier bushing bolts.

To remove the axleshaft, you push the outer (flanged) end of the axleshaft in and remove the C-lock from the inner end of the shaft. Then, you withdraw the axleshaft, being careful not to damage the oil seal in the end of the axle housing as the splined end of the axleshaft passes through it.