Axle Shaft: Removal

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.

Position the vehicle on a hoist. For additional information, refer to JACKING & HOISTING .

CAUTION: Do not use heat to loosen a seized wheel nut. Heat can damage the wheel and the rear wheel bearings.

Loosen the wheel nuts.
1. Remove the center cap.
2. With the weight of the vehicle on the wheels, loosen the wheel nuts. For additional information, refer to WHEELS AND TIRES .
  
  Fig 1: Loosening Wheel Nuts
  Courtesy of FORD MOTOR CO.

WARNING: When equipped with rear air springs, the electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the LH side of the luggage compartment. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations.

Fig 2: Turning Air Suspension Switch Off

Courtesy of FORD MOTOR CO.

Turn the air suspension switch off.
Remove the rear wheel and tire assembly.
1. Remove the wheel nuts.
2. Remove the wheel and tire assembly.
  - For additional information, refer to WHEELS AND TIRES .
  Fig 3: Removing Rear Wheel And Tire Assembly
  Courtesy of FORD MOTOR CO.
Remove the differential housing cover.
1. Remove the 10 differential housing cover bolts and drain the lubricant from the rear axle housing.
2. Remove the differential housing cover.
  
  Fig 4: Removing Differential Housing Cover
  Courtesy of FORD MOTOR CO.
Remove the rear brake anti-lock sensor. For additional information, refer to ANTI-LOCK CONTROL - TRACTION CONTROL .

Fig 5: Removing Rear Brake Anti-Lock Sensor
Courtesy of FORD MOTOR CO.

NOTE: When removing the rear brake caliper in this procedure, it is not necessary to disconnect the hydraulic lines.

Remove the rear brake caliper and the brake disc. For additional information, refer to DISC .
- Support the rear brake caliper with mechanics wire.
  
  Fig 6: Removing Rear Brake Caliper And Brake Disc
  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.

Remove the differential pinion shaft.
1. Remove the differential pinion shaft lock bolt.
2. Remove the differential pinion shaft.
  
  Fig 7: Removing Differential Pinion Shaft
  Courtesy of FORD MOTOR CO.

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

Remove the U-washer.
1. Push the axle shaft inboard.
2. Remove the U-washer.
  
  Fig 8: Removing U-Washer
  Courtesy of FORD MOTOR CO.
Reinstall the differential pinion shaft.
1. Push the axle shaft outboard.
2. Install the differential pinion shaft.
3. Install the differential pinion shaft lock bolt finger-tight.
  
  Fig 9: Reinstalling Differential Pinion Shaft
  Courtesy of FORD MOTOR CO.

CAUTION: Do not damage the wheel bearing oil seal.

Fig 10: Removing Axle Shaft

Courtesy of FORD MOTOR CO.

Remove the axle shaft.
Using a thin-blade cold chisel between the rear brake anti-lock sensor indicator and the axle shaft, strike the chisel evenly around the flange. Force the rear anti-lock sensor indicator off the rear brake anti-lock sensor indicator journal. Discard the rear brake anti-lock sensor indicator.

Fig 11: Discarding Rear Brake Anti-Lock Sensor Indicator
Courtesy of FORD MOTOR CO.