How to Change an Axle Shaft in a 2003 Ford F-150

The Ford F-150 has a longstanding tradition of having a wide array of options and formats to choose from, to better meet the precise needs of most buyers. The rear axle of the 2003 F-150 came in three different sizes: 8.8 inch, 9.75 inch and 10.25 inch. All three sizes also came either standard or with Fords limited slip feature, Traction-Lok. Replacing the axle shaft in all of the different formats is the same process, which is surprisingly straightforward.

Instructions

Removal

1

Disable the air suspension by turning the toggle switch on the passenger's side kick panel to the "Off" position. Slide wheel chocks under the front wheels. Loosen the rear lug nuts from the wheel with the bad axle shaft, using a ratchet and socket, and lift the rear of the F-150 with a floor jack. Slide jack stands under the trucks frame rails and lower the F-150 onto the jack stands. Remove the lug nuts and pull the wheel off the truck.

2

Remove the caliper bolts with a ratchet and socket and pull the caliper and brake pads off the caliper bracket. Hang the caliper from the frame with a bungee strap. Pull the rear rotor from the rear hub. If needed, lightly tap the rear of the rotor with a rubber mallet to free it.

3

Slide a drain pan under the rear axles center differential. Remove the bolts securing the cover to the differential, using a ratchet and socket. Pull the differential cover from the differential and allow all of the gear oil to drain into the drain pan.

4

Loosen the differential pinion shaft bolt, the horizontal bolt that locks the differential pinion shaft in place. Remove the pinion shaft bolt with a ratchet and socket and remove the pinion shaft. Discard the pinion shaft lock bolt if you are replacing it with a new one.

5

Push the defective axle shaft inward toward the differential. Pull the U-shaped washer from the end of the axle shaft inside the differential, using needle-nose pliers.

6

Grab the outermost part of the axle shaft and pull it out from the axle tube to remove it.

7

Pull the oil seal from the axle tube with a seal puller.

Installation

8

Drive a new oil seal into the axle tube, using an axle oil seal installer and hammer. Apply a thin coat of multipurpose grease onto the lip of the new oil seal.

9

Slide a new axle shaft into the axle tube until the groove on the innermost part of the axle is exposed inside the differential. Press the U-shaped washer into the groove on the innermost part of the axle.

10

Slide the differential pinion shaft into its hole in the rear differential, aligning its bolt hole with the case lock bolt hole, the hole that the pinion shaft lock bolt threads into.

11

Thread a new pinion shaft lock bolt into the case lock bolt hole, then torque it to between 15 and 30 foot-pounds on 8.8-inch and 10.25-inch ring gear axles or 22 foot-pounds on a 9.75-inch axle, using a torque wrench and socket. If you cannot obtain a pinion shaft lock bolt, coat the original bolt with a thread-locking chemical before installing it.

12

Slide the rotor onto the rear hub and set the caliper and brake pads on the caliper bracket. Hand-thread the caliper bolts, then torque them to 20 foot-pounds.

13

Clean the mating surface on the rear differential and its cover, using a plastic gasket scraper and a clean, lint-free cloth.

14

Apply a continuous bead of silicone meeting Ford specification ESB-M4G92-A or ESE-M4G195-A around the mating surface of the differential cover, going to the inside of the bolt holes. Position the cover on the differential and hand-thread the covers retaining bolts; torque the bolts, in a crisscross pattern, to 33 foot-pounds, or 28 to 38 foot-pounds on the 10.25-inch axle. You must install the cover within 15 minutes of applying the silicone. If you wait longer than 15 minutes, remove the silicone and reapply it.

15

Allow the silicone to dry for about an hour.

16

Remove the check-and-fill plug from the front of the differential, using a ratchet, and add 4 ounces of an XL-3 friction modifier meeting Ford specification EST-M2C118-A on 8.8-inch and 9.75-inch axles, or 8 ounces on 10.25-inch axles, if the gear oil you are using does not already have the modifier in it and your F-150 has a Traction-Lok axle. Add SAE 75W-140 synthetic rear axle lubricant through the check-and-fill hole until the lubricant drips from the hole.

17

Clean the check-and-fill plug with a clean, lint-free cloth and hand-thread it into the differential. Tighten the check-and-fill plug to 22 foot-pounds.

18

Reinstall the rear wheel and hand-thread its lug nuts. Raise the rear of the F-150 off the jack stands with a floor jack and remove the jack stands. Lower the truck to the ground and torque the lug nuts, in a crisscross pattern, to 100 foot-pounds on 12 mm wheel bolts or 150 foot-pounds on 14 mm wheel bolts.

19

Take the old gear oil to a used automotive fluid recycler. Some auto parts stores take old fluids free of charge.