repair manual covers Ford Super Duty F-250 and Super Duty F-350 pickup trucks 1999-2006, and Ford Excursion SUVs 2000-2005. Covers 2WD and 4WD with gasoline and diesel engines.
What’s Inside?
Introduction: About this manual | Introduction | Vehicle identification numbers | Maintenance techniques, tools and working facilities | Buying parts | Jacking and towing | Anti-theft audio system | Booster battery (jump) starting | Conversion factors | Automotive chemicals and lubricants | Safety first! | Troubleshooting

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Axle Shaft Removal 1. NOTE: The wheels and tires do not have to be removed in order to remove the axle shafts. Loosen and remove the retaining bolts. 2. Remove the axle shaft. 3. Inspect the axle shaft O-ring seal for cracks, nicks or wear and replace it if required. Installation NOTE: Lubricate the O-ring seal with lubricant prior to installation of axle shaft. 1. Install the axle shaft. 2. NOTE: Coat the threads of the retaining bolts with stud and bearing mount. Install the retaining bolts and tighten.

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Some 1998-2003 E-Series, 1999-2003 Super Duty, 2000-2003 Excursion, and 2000-2003 F650/750 vehicles equipped with a 7.3L Diesel engine may exhibit an oil leak at the high pressure oil pump outlet fittings and/or end plug (see Figure 1). The leak may appear to be a rear main crankshaft seal, oil pan gasket, or other engine oil leak due to the drain hole machined in the crankcase valley which allows any oil in the valley to run down the back of the engine. ACTION High pressure oil pump leaks at the outlet fittings and/or end plug can be serviced without removing the pump assembly. Replace the O-rings on the fittings and the end plug using Kit 2C3Z-9G804-AA. All three (3) O-rings should be replaced. Apply liquid thread sealer (included in the kit) prior to reinstallation. Refer to the following Service Procedure for details.

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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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NOTE: Unless noted, the procedures in this section apply to both the conventional differential and the Truetrac® differential, though most of the illustrations used in the procedures show the conventional differential. The Model S135 rear axle features the following: a hypoid design differential ring gear and pinion a two-bearing overhung pinion mounting full-floating axle shafts a steel differential housing a front mounted removable one-piece carrier housing a conventional differential assembly or a Truetrac® limited slip differential assembly The trademark shows the company logo, and identifies the location of the manufacturing facility. CAUTION: Never mate a differential ring gear and pinion together that does not have the same matched set numbers. Always install a new matched set if discarding either the differential ring gear or the pinion. A corresponding number marked on the differential ring gear and pinion identifies them as a matched set. The manufacturer’s date identifies the gear set’s date of fabrication. The tooth combination identifies the number of teeth on the pinion and the number of teeth on the differential ring gear. A tooth combination of 41-11, for example, would indicate that the pinion has 11 teeth and the ring gear has 41 teeth that results in a 3.73:1 ratio. Dana Model S135 Full-Floating Rear Axle, Disassembled View