Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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1. With the vehicle in NEUTRAL, position on a hoist. For additional information, refer to Section 100-00. 2. Remove the rear wheel and tire assembly. For additional information, refer to Section 204-00. 3. Remove the parts in the order indicated in the following illustration and table. 4. To install, reverse the removal procedure. 5. Fill the axle with the specified quantity of the specified lubricant. For additional information, refer to the Specifications in this section. Item 2: Rear Disc Brake Caliper Removal Note 1. CAUTION: Do not allow the caliper to hang from the brake hose. Provide a suitable support. Position the rear disc brake caliper aside. For additional information, refer to Section 206-00. Item 7: Differential Pinion Shaft Removal Note 1. Move the differential pinion shaft out far enough to remove the U-washers. Replace the shaft and install the lock bolt finger tight when U-washers are removed. Item 8: U-washer Removal Note 1. CAUTION: Do not damage the rubber O-rings in the axle shaft grooves. Remove the U-washers. 1. Push the axle shafts inboard. 2. Remove the U-washers. Item 10 and 11: Wheel Bearing Oil Seal and Axle Shaft Bearing Removal Note 1. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the wheel bearing oil seal and the rear wheel bearing at the same time. For the 8.8 inch rear axle, use the special tools to remove the rear wheel bearing and wheel bearing oil seal. 2. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the wheel bearing oil seal and the rear wheel bearing at the same time. For the 9.75 inch and the 10.25 inch rear axles, use the special tools to remove the rear wheel bearing and wheel bearing oil seal. Item 11: Axle Shaft Bearing Installation Note 1. For the 8.8 inch and the 9.75 inch rear axles, use the special tools to install the rear axle wheel bearing. 2. For the 10.25 inch rear axle, use the special tools shown to install the rear axle wheel bearing. Item 10: Wheel Bearing Oil Seal Installation Note 1. Use the special tools shown to install the rear wheel bearing oil seal. Item 8: U-washer Installation Note 1. CAUTION: Do not damage the rubber O-rings in the U-washer grooves. Install the U-washers. 1. Position the two U-washers on the button end of the axle shafts. 2. Pull the axle shafts outward.

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Removal NOTE: If, for any reason, the rear hub (1109) is removed from the spindle, the old hub seal must be removed and a new hub seal installed. 1. Set the parking brake and loosen the eight axle shaft retaining bolts. 2. Raise the vehicle to the desired working height, keeping the axle parallel with the floor. 3. Release parking brake and back off the rear brake adjustment, if necessary. 4. Remove the wheel (1007). 5. Remove brake drum (1126). Push-on (sheet metal) drum retainer nuts may be discarded. Push-on retainer nuts are used for shipping purposes only and have no vehicle function. If retainers are not flush against the drum, the retainers can prevent the wheel from being flat against the drum, which could contribute to vibration. 6. Place a drain pan under the axle shaft (4234) and rear hub. Remove the eight 7/16-inch axle shaft bolts and remove the axle shaft. Axle Shaft Removal 7. CAUTION: The right hub nuts are right-hand thread; the left hub nuts are left-hand thread. Each hub nut is stamped RH for the right hub nut or LH for the left hub nut. Install Locknut Wrench T85T-4252-AH so that the drive tangs of the tool engage the four slots in the hub nut. 8. CAUTION: A new hub nut must be installed if used hub nut comes apart during removal or installation. CAUTION: Under no circumstances are power impact tools to be used when performing these operations. NOTE: The hub nut will ratchet during this operation. Remove hub nut (counterclockwise for right-hand thread; clockwise for left-hand thread). 9. Install Step Plate Adapter D80L-630-7 (Part of Step Plate Adapter Set D80L-630-A) or equivalent. 10. Install 2-Jaw Puller D80L-1002-L or equivalent and loosen rear hub to the point of removal. 11. CAUTION: Do not drop outer hub bearing when removing. Remove rear hub assembly.

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Tools Required J 45859 Axle Remover Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 3. Remove the rotor. Refer to Brake Rotor Replacement – Front in Disc Brakes. Fig. 62: View Of Retaining Bolts For Brake Hose And Wheel Speed Sensor Brackets Fig. 63: Removing The Wheel Drive Shaft Nut Retaining Cover (4WD)

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90 Nm + 45 ° ( 1 / 8 ) additional turn. loosening and tightening Remove any paint residue and/or corrosion in the threads of outer joint before screwing on nut. 3 – Phillips-head screw 4 – Brake disc Notes for repairing 5 – Brake caliper Do not remove brake hose when working on front wheel suspension Hang with wire or similar means Replace brake pads 6 – Metal countersunk screw 7 – Wheel hub Pressing out Pressing in Remove bearing inner race 8 – Rotor for speed sensor Only on vehicles with ABS Front brakes – brake caliper Girling, servicing Brake pads, removing and installing 9 – Hex bolt, 10 Nm 10 – Cover plate 11 – Securing ring Check for proper seating 12 – Wheel bearing Pressing out Replace, destroyed during ejection Pressing in 13 – Self-locking hex nut, 35 Nm 14 – Wheel bearing housing 15 – Ribbed bolt, 125 Nm 16 – Drive axle Removing and installing Servicing 17 – Multipoint socket head bolt, 45 Nm 18 – Hex bolt Camber setting Drive axle with triple rotor joint, removing and installing Drive axle, servicing Camber of front wheels, adjusting Mark installation position before loosening 19 – Hex bolt 20 – Bracket 21 – Stop 22 – Self-locking hex nut, 60 Nm unbolt and bolt in 23 – Suspension strut Disassembling and assembling 24 – Self-locking hex nut, 95 Nm 25 – Tie rod Removing and installing Front suspension strut – Basic/Plus suspensions, servicing Tie rod – power steering gear, TRW and ZF, removing and installing

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CAUTION: Use of incompatible bearing lubricant could result in premature lubricant breakdown. The recommended wheel bearing lubricant is the lithium-base grease High Temperature 4×4 Front Axle and Wheel Bearing Grease E8TZ-19590-A or equivalent meeting Ford specification ESA-M1C198-A. Sodium-base grease is not compatible with lithium-base grease and should not be intermixed. Therefore, before lubricating front or rear wheel bearings (1225), thoroughly clean all old grease from the bearing and front disc brake hub and rotor (1102). If bearing adjustment does not eliminate looseness or rough and noisy operation, clean and inspect the front disc brake hub and rotor and bearings. If bearing cups or the cone and roller assemblies are worn or damaged, replace. Disassembly 1. Raise vehicle and install safety stands. 2. Remove the wheel and tire. Refer to Section 04-04 in the Body, Chassis Manual. 3. Remove the locking hubs. 4. CAUTION: Do not let the disc brake caliper (2B120) hang only by the hose, or damage might occur to the hose or disc brake caliper. Remove the disc brake caliper. Refer to Section 06-03 in the Body, Chassis manual. Securely wire the disc brake caliper to the frame. 5. For vehicles equipped with automatic locking hubs, remove C-ring or snap ring and three-piece thrust washers (spacers). Remove the cam assembly and wheel bearing nut retaining key. Remove wheel bearing retainer (nut) using Hub Nut Wrench T95T-1197-B. Repack the wheel bearings with the specified lubricant (grease). For vehicles with manual locking hubs, remove snap ring, three-piece thrust washers (spacers), the outer lock nut, lockwasher, and inner lock nut using Spanner Locknut Wrench D85T- 1197-A or equivalent. 6. Remove the front disc brake hub and rotor. The front outer wheel bearing will slide out as the hub is removed. 7. Remove the retaining nuts of the front wheel spindle (3105). Carefully remove the front wheel spindle from the knuckle studs and halfshaft (3A329). If necessary, lightly tap the end of the spindle with a rawhide hammer to remove. 8. Clean old grease from the needle bearings and the bore seal of the front wheel spindle. To replace spindle bearing or inner seal, refer to Section 05-03A or Section 05-03B. 9. Clean any old grease or dirt from these parts and replace if signs of excessive wear are noted. Assembly 1. Using High-Temperature 4×4 Front Axle and Wheel Bearing Grease E8TZ-19590-A or equivalent meeting Ford specification ESA-M1C198-A, thoroughly lubricate the needle bearing and coat the front wheel spindles or face that mates with the seals of the front wheel spindle. 2. Assemble the front wheel spindle over the halfshaft onto the knuckle studs. Tighten the retaining nuts to 68-81 Nm (50-60 lb-ft). 3. Remove the front inner wheel bearing, wheel hub grease seal (1190) from the front disc brake hub and rotor using Bearing Cup Puller T77F-1102-A and Impact Slide Hammer T50T-100-A. Inspect bearings and replace as necessary. 4. Inspect the bearing cups for pits or cracks. If necessary, remove with a drift. If new cups are installed, install new cones and rollers. 5. Lubricate the bearings with High Temperature 4×4 Front Axle and Wheel Bearing Grease E8TZ-19590-A or equivalent meeting Ford Specification ESA-M1C198-A. Clean all old grease from the front disc brake hub and rotor. Pack the cones and rollers. If a bearing packer is not available, work as much lubricant as possible between the rollers and the cages. 6. Position the front inner wheel bearing in the inner cup and install the new wheel hub grease seal using a hammer, Driver Handle T80T-4000-W and the proper seal installer.