Ford 6W1Z-4234-A Shaft Assembly - Rear Axle

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To remove the rear axle assembly, disconnect the battery cable, loosen lug nuts, raise the vehicle, remove wheels, brake components, and axle cover. Disconnect ABS sensors, axleshafts, brake lines, and backing plates. Unbolt driveshaft, raise axle, disconnect safety chain or air springs, remove shock absorbers and suspension arm bolts. Disconnect axle-locating arms, Watts-linkage assembly, and height sensor if applicable. Lower axle housing, remove coil springs or air springs. Lower suspension arm bolts, remove axle housing. For installation, raise axle, secure with suspension arm bolts, install springs, connect lower suspension arms. Raise axle to normal height, tighten suspension arm bolts, reattach height sensor if applicable. Connect shock absorbers, driveshaft, and backing plates. Reconnect sensor wires, brake lines, and parking brake cables. Install axleshafts, brake components, axle cover, and fill differential. Install wheels, lower vehicle, and tighten lug nuts.

Loosen the wheel lug nuts, raise the rear of the vehicle, support it securely on jackstands and remove the wheel. Also remove the brake drum, or the caliper and disc. Remove the cover from the differential carrier and allow the lubricant to drain into a container. Remove the lock bolt from the differential pinion shaft. Slide the notched end of the pinion shaft out of the differential case as far as ii will go. Position a large screwdriver between the rear axle case and a ring gear bolt to keep the differential case from turning when removing the pinion shaft lock bolt. 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. Push the outer (flanged) end of the axleshaft in and remove the C-lock from the inner end of the shaft. Take care to not damage the 0- rings in the axleshaft grooves when removing the C-clips. Withdraw the axleshaft, taking care not to damage the oil seal in the end of the axle housing as the splined end of the axleshaft passes through it. Do not rotate the differential while the pinion shaft is out, or the pinion gears could fall out. Installation is the reverse of removal. Tighten the differential pinion shaft lock bolt to the torque Specifications. Install the differential cover. Refill the axle with the correct quantity and grade of lubricant.

Loosen the wheel lug nuts, raise the rear of the vehicle, support it securely on jackstands and remove the wheel. Also remove the brake drum, or the caliper and disc. Remove the cover from the differential carrier and allow the lubricant to drain into a container. Remove the lock bolt from the differential pinion shaft. Slide the notched end of the pinion shaft out of the differential case as far as ii will go. Position a large screwdriver between the rear axle case and a ring gear bolt to keep the differential case from turning when removing the pinion shaft lock bolt. 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. Push the outer (flanged) end of the axleshaft in and remove the C-lock from the inner end of the shaft. Take care to not damage the 0- rings in the axleshaft grooves when removing the C-clips. Withdraw the axleshaft, taking care not to damage the oil seal in the end of the axle housing as the splined end of the axleshaft passes through it. Do not rotate the differential while the pinion shaft is out, or the pinion gears could fall out. Installation is the reverse of removal. Tighten the differential pinion shaft lock bolt to the torque Specifications. Install the differential cover. Refill the axle with the correct quantity and grade of lubricant.

Unbolt the driveshaft from the differential companion flange and wire it aside. Place a floor jack under the differential and raise the rear axle slightly. If applicable, disconnect the safety chain through the coil springs or disconnect the air springs.