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

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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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1. Raise the vehicle on a hoist or raise the rear end of the vehicle with a jack. Install safety stands under the frame rails and lower the jack or hoist enough to allow the rear axle to drop into the rebound position for working clearance. For additional information, refer to Section 100-02. 2. Remove the rear wheel and tire assembly. For additional information, refer to Section 204-04. 3. Remove the brake drum. For additional information, refer to Section 206-02. 4. Remove the differential housing cover (4033) and drain the lubricant. Clean the gasket material from the differential housing cover and the differential housing (4010). 5. CAUTION: The differential assembly is equipped with either a Loctite® coated differential pinion shaft lock screw or a differential pinion shaft lock screw with torque prevailing threads. The Loctite® treated differential pinion shaft lock screw has a 5/32-inch hexagram socket head. Never, under any circumstance, reuse a Loctite® coated screw after removing it. Always discard the screw and install a new one. The torque prevailing differential pinion shaft lock screw has a 12-point drive head. This type of screw is reusable for no more than four installations. When in doubt about the number of installations of a torque prevailing differential pinion shaft lock screw, discard it and install a new screw. Remove the lock screw. 6. Remove the differential pinion shaft (4211). The pinion shaft is a slip-fit design and is removable by hand. 7. Push the flanged end of the axle shaft (4234) toward the center of the axle and remove the U-washer (4N237).

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SERVICE PROCEDURE 1. Raise the vehicle off the ground with a vehicle hoist. 2. Remove the right rear wheel. 3. Remove 2 bolts from the fuel filler tube bracket. 4. Remove the plastic cover (4 clips). 5. Unhook the fuel filler tube bracket from the body. 6. Unclip the recirculation tube. 7. Apply auto body painting tape to the top and rear of the wheel opening as shown. NOTE: This tape will protect the paint during the procedure. 8. Use a protective cloth to cover the items shown in Figure 6. 9. Remove the fuel filler cap and install a spare fuel fill cap. NOTE: If a spare fuel filler cap is not available, disconnect the tether and leave the original cap in place. 10. Hold the fuel filler tube with both hands and carefully pull the flange loose from the fuel door opening. WARNING: Make sure the fuel filler cap is installed and tight. If the fuel filler cap is not installed and tight, fuel may leak from the fuel filler tube when it is lowered. 11. Carefully pull down on the fuel filler tube and then pull the top of the tube from the wheel well (see Figure 8). • Do not scratch or chip the fuel filler tube paint. • Do not pull, stretch, or stress the fuel filler rubber tube. 12. Rest the fuel filler tube on the brake drum. WARNING: Do not remove the fuel fuller cap with the fuel filler tube in this position. Fuel may leak from the fuel filler tube. 13. Thoroughly clean the following with isopropyl alcohol: • Flange • Fuel filler tube, 6 inches from the flange • Recirculation tube, 6 inches from the flange

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Some vehicles may exhibit a grabbing condition from the rear brakes during the first few brake applications. The condition only occurs after the vehicle has been parked for several hours. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE To service, reduce/minimize moisture intrusion into the rear drum brake assemblies by applying Motorcraft® Silicone Gasket and Sealant to the brake backing plate. 1. Place vehicle on hoist and remove the rear wheels. 2. Remove the rear brake drums and replace the rear linings. Refer to Workshop Manual (WSM), Section 206-02. WARNING Do not breathe dust or use compressed air to blow dust from storage containers or friction components. Remove dust using government-approved techniques. Friction component dust may be a cancer and lung disease hazard. Exposure to potentially hazardous components may occur if dusts are created during repair of friction components, such as brake pads and clutch discs. Exposure may also cause irritation to skin, eyes and respiratory tract, and may cause allergic reactions and/or may lead to other chronic health effects. If irritation persists, seek medical attention or advice. Failure to follow these instructions may result in serious personal injury. 3. Inspect the rear brake assemblies for damaged, missing and/or improperly seated adjuster plug or parking brake cable. 4. Inspect and clean the lining contact area of the brake drum; machine if necessary. 5. Reinstall the rear brake drums and adjust the lining to drum clearance per WSM, Section 206-02. 6. Thoroughly clean the backside of the rear drum brake backing plate to promote proper adhesion of sealant. 7. Apply Motorcraft(R) Silicone Gasket and Sealant to the backside of the rear drum brake backing plate at the following inter[ace areas (Figure 1): ^ Axle Flange ^ Wheel Cylinder ^ Parking Brake Cable ^ Hold Down Pins NOTE AVOID GETTING SEALANT ON THE BRAKE BLEED SCREW AND BRAKE TUBE NUT. 8. Reinstall the rear wheels and torque lug nuts per Workshop Manual, Section 204-04.

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REMOVAL 1. Remove the tire and wheel assembly from the vehicle. Remove the park brake cable for the wheel of the vehicle that is being worked on, from the parking brake cable equalizer). This is required to gain access to the star wheel. If the cable is not removed from the equalizer, the cable and spring inside of the brake drum is in the way of the star wheel. 2. Remove the rear brake shoe adjusting hole cover plug. 3. Insert a thin screwdriver into brake adjusting hole and hold adjusting lever away from notches of adjusting screw star wheel. 4. Insert Tool C-3784 into brake adjusting hole and engage notches of brake adjusting screw star wheel. Release brake adjustment by prying down with adjusting tool. 5. Remove rear brake drum from rear hub/bearing assembly. INSTALLATION 1. Adjust brake shoe assemblies so as not to interfere with brake drum installation. 2. Install the rear brake drums on the hubs. 3. Adjust rear brake shoes. 4. Install the removed park brake cable back on the park brake cable equalizer. 5. Install wheel and tire. 6. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.).