How to Replace an Axle Shaft for 1995 Mustangs, Rangers and Explorers

The 1995 Ford rear-wheel drive vehicles like the Mustang, Ranger and Explorer all came with an 8.8-inch rear differential in both open and limited slip configuration. One of the common problems with this differential is damage to the bearing surface on the passenger-side axle caused by leaking axle seals. The only way to repair this kind of damage is to replace the axle with a new unit. The experienced home mechanic can complete this repair in an afternoon using basic tools and equipment.

Instructions

1

Securely block the front wheels using wheel chocks wedged against the front and back of the tires. Loosen, but do not remove the lug nuts on the rear wheels with the lug wrench. Place the transmission in neutral. Lift the rear of the Ford using a floor jack positioned under the center of the rear differential. Position jack stands under the rear axle tubes and lower the jack until the car rests on the stands. Remove the rear wheels using the lug wrench.

2

Slide the rear brake drum off the brake shoes on vehicles equipped with rear drum brakes. Remove the two 13-mm caliper slide bolts using a wrench, slide the caliper up over the rotor and slide the rotor off the axle on vehicles equipped with rear disc brakes.

3

Position the drain pan under the differential below the differential cover. Loosen the rear differential cover bolts using a 13-mm wrench or socket and ratchet. Allow the differential fluid to drain into the drain pan. Remove the differential cover bolts and lower the differential cover into the drain pan when the fluid has completely drained.

4

Rotate the drive shaft until the 8-mm bolt that secures the large shaft in the center of the differential carrier is accessible. Remove the 8-mm bolt and slide the shaft out of the differential. From this point on, do not rotate the assembly or the gears will drop out of the carrier.

5

Push the outside axle flange towards the center of the differential. Slide the C-clip off the end of the axle from the center of the differential. Pull the axle out of the differential and axle tube from the wheel-end of the axle tube.

6

Slide the new axle into the axle tube. Rotate the axle until the splines on the end of the axle align with the splines on the gears in the differential. Push the axle into the differential and reinstall the C-clip on the end of the axle.

7

Slide the differential center shaft into the differential through the gears and reinstall the 8-mm bolt. Torque the bolt to between 15 and 30 inch pounds using a torque wrench. Clean the old gasket material from the mounting flange of both the differential and the differential cover using a gasket scraper and spray parts cleaner.

8

Apply a 1/4-inch bead of silicon gasket maker to the differential cover and wait 15 minutes for a skin to form on the silicon. Reinstall the differential cover and torque the bolts to between 18- and 28-foot pounds using a torque wrench. Slide the brake drum onto the brakes shoes or the rotor onto the axle. Reinstall the brake calipers and torque the bolts to 95-foot pounds.

9

Remove the fill plug on the passenger side of the differential above and in front of the axle, using a 3/8-inch ratchet and extension. Fill the differential with 3.75 pints of with 80- or 90-weight "Hypoid Gear Oil'. Add four ounces of Ford Friction Modifier if the differential is equipped with a Traction-Loc limited slip. Reinstall the fill plug.

10

Reinstall the wheels. Raise the vehicle off the jack stands and remove the stands. Lower the jack until the wheels just touch the ground and torque the lug nuts to 100-foot pounds. Lower the vehicle to the ground and slide the jack from under the car. Test drive the vehicle and check for leaks.