Section 05-02G: Axle, Integral Carrier, 8.8-Inch Ring Gear
1996 F-150 and Bronco Workshop Manual
REMOVAL AND INSTALLATION

Cover

 
 

Removal

  1. Raise vehicle and install safety stands.

  1. Clean all dirt from the area of axle housing cover (4033) with a wire brush.

  1. Loosen axle housing cover and drain lubricant from rear axle housing (4010). Remove axle housing cover.

 

Installation

  1.  CAUTION: Make sure machined surfaces on both axle housing cover and carrier are clean and free of oil before installing the new silicone sealant. Inside of rear axle (4001) must be covered when cleaning the machined surface to prevent contamination.

    Clean the gasket mating surface of the rear axle carrier casting and axle housing cover.

  1. Apply a new continuous bead of Silicone Rubber D6AZ-19562-AA or -BA or equivalent meeting Ford specifications ESB-M4G92-A and ESE-M4G195-A to the new axle housing cover.

  1. NOTE: Axle housing cover must be installed within 15 minutes of application of the silicone or new sealant must be applied. If time permits, allow one hour before filling with lubricant to make sure silicone sealant has properly cured.

    Install axle housing cover and tighten bolts to 38-52 Nm (28-38 lb-ft). Tighten the cover bolts in a cross-wise pattern to maintain axle housing cover flatness.

  1. Add lubricant through the filler hole until the lubricant level is 6.4-14.2mm (1/4 to 9/16 inch) below the bottom of the filler hole with the axle in the running position. Add 5.5 pints of Premium Rear Axle Lubricant XY-80W90-QL or -KL or equivalent meeting Ford specification WSP-M2C197-A, plus 4 ounces of Ford Friction Modifier (for Traction-Lok® axles) F3TZ-19B546-MA or equivalent meeting Ford specification WSP-M2C196-A. Install the filler plug and tighten to 20-40 Nm (15-30 lb-ft).

  1. Remove safety stands. Lower vehicle and road test.