Axle Shaft - Rear

This procedure covers the removal and replacement of the rear axle shaft on a 2011-2014 Ford F-150 with 3.5L EcoBoost and 4WD, including differential fluid drain and refill.

Warnings

Tools required

Parts

• Rear axle shaft assembly × 1 — Use OEM specification for correct length and spline count
• Axle shaft seal × 1 — Use OEM specification
• Differential cover gasket × 1 — Use OEM specification or RTV sealant
• Axle nut cotter pin or stake washer × 1 — Use OEM specification

Fluids

• Motorcraft 75W-140 Synthetic Gear Oil — 2 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Chock the front wheels securely
3. Loosen rear wheel lug nuts while vehicle is on ground
4. Raise rear of vehicle and support securely on jack stands at frame rails
5. Remove rear wheels completely
6. Place drain pan under rear differential
7. Allow differential to cool if vehicle was recently driven

Procedure

1. 1

   Remove differential cover
   Loosen all differential cover bolts in a crisscross pattern. Remove all but the top two bolts completely, then carefully loosen the remaining bolts while supporting the cover. Allow differential fluid to drain into pan. Once drained, remove cover and gasket material. Clean the cover and housing mating surfaces with a wire brush and brake cleaner.
   Torque spec

   Differential Cover Bolts35 Nm (26 lb-ft)
2. 2

   Remove axle nut retention
   Locate the axle nut at the wheel hub. If secured with a cotter pin, remove and discard the pin. If the nut is staked, use a punch and hammer to carefully unstake the nut collar from the axle groove. Do not reuse cotter pins or attempt to restake the original nut.
   ℹ️Axle nut type varies by production date. Inspect carefully to determine retention method before proceeding.
   Torque spec

   Axle Nut250 Nm (184 lb-ft)
3. 3

   Remove axle shaft nut
   Using a breaker bar and appropriate socket, remove the axle shaft nut from the hub. This nut is torqued to 250 Nm and will require significant force. Have an assistant apply the brakes or use a pry bar against the wheel studs to prevent rotation. Remove nut completely and set aside (do not reuse if staked).
   ⚠The axle nut is under high torque. Ensure the socket is fully seated to prevent rounding.
   Torque spec

   Axle Nut250 Nm (184 lb-ft)
4. 4

   Disconnect axle from hub
   With the nut removed, the axle shaft outer end should be free from the hub assembly. If the splines are stuck, use a brass drift or rubber mallet to tap the end of the axle shaft to break it free. Push the axle shaft inward slightly to disengage it from the hub bearing.
5. 5

   Access differential C-clip or retainer
   Through the differential cover opening, rotate the axle shaft and differential assembly to locate the axle shaft retaining C-clip inside the differential carrier. On this axle design, you may need to remove the differential pinion shaft lock bolt and pinion shaft to access the C-clip. Use a socket and ratchet to remove the lock bolt.
   ℹ️Some fluid will continue to seep from the differential. Keep the drain pan in place.
6. 6

   Remove pinion shaft and C-clip
   After removing the lock bolt, carefully pull the pinion shaft out of the differential case. Push the axle shaft inward toward the differential to expose the C-clip groove. Use a magnetic pick or small screwdriver to remove the C-clip from the axle shaft groove inside the differential. Keep track of the C-clip as it will be reused or replaced.
7. 7

   Remove axle shaft from housing
   With the C-clip removed, carefully pull the axle shaft outward from the axle housing. The shaft should slide out with moderate resistance. If the shaft is seized, attach a slide hammer to the axle flange or use the slide hammer with an internal puller attachment. Apply steady force until the shaft releases. Be prepared for additional fluid drainage as the shaft exits the housing.
   ⚠Do not damage the axle seal during removal. The bearing and seal will remain in the housing and may need inspection or replacement.
8. 8

   Inspect and replace axle seal
   With the axle shaft removed, inspect the axle seal in the housing. If replacing the axle shaft, the seal should be replaced as well. Use a seal puller or slide hammer with seal puller attachment to remove the old seal. Clean the seal bore thoroughly. Install the new seal using a seal driver or large socket, ensuring it seats fully and squarely in the bore. Apply a light coat of differential fluid to the seal lip.
9. 9

   Install new axle shaft
   Inspect the new axle shaft splines and bearing surface. Apply a light coat of differential fluid to the bearing journal and seal contact area. Carefully slide the new axle shaft into the housing, ensuring it does not damage the new seal. Push the shaft in until it bottoms against the differential side gear.
10. 10

    Install C-clip and pinion shaft
    Push the axle shaft inward and install the C-clip into the groove on the inner end of the axle shaft. Pull the axle shaft outward to verify the C-clip is properly seated. Reinstall the differential pinion shaft through the case and side gears, aligning the lock bolt hole. Install and hand-tighten the pinion shaft lock bolt.
11. 11

    Reinstall differential cover
    Clean all old gasket material from the differential cover and housing surfaces. Install a new gasket or apply a continuous bead of RTV sealant to the cover mating surface. Position the cover on the housing and install all bolts hand-tight. Torque the differential cover bolts in a crisscross pattern to specification.
    ℹ️If using RTV sealant, allow appropriate cure time per manufacturer instructions before refilling with fluid.
    Torque spec

    Differential Cover Bolts35 Nm (26 lb-ft)
12. 12

    Refill differential with fluid
    Locate the differential fill plug on the front of the differential housing. Remove the fill plug. Using a fluid pump, add Motorcraft 75W-140 Synthetic Gear Oil through the fill hole until fluid begins to drip from the fill hole opening. Install the fill plug and torque to specification if equipped with a torque requirement, or snug securely.
13. 13

    Connect axle shaft to hub
    Align the axle shaft splines with the hub bearing and carefully push the shaft outward until it fully engages the hub splines. Install the axle shaft nut and thread it on by hand as far as possible. Torque the axle nut to specification using a torque wrench.
    ⚠Ensure axle splines are properly aligned before forcing the connection. Cross-threading or misalignment can damage the hub bearing.
    Torque spec

    Axle Nut250 Nm (184 lb-ft)
14. 14

    Secure axle nut
    After torquing the axle nut to 250 Nm, install the retention device. If using a cotter pin design, install a new cotter pin through the hole in the axle shaft and bend the ends to secure. If using a staked nut design, use a punch to stake the nut collar into the axle shaft groove at the designated staking points. Verify the nut cannot rotate.
    ⚠Never reuse cotter pins or previously staked nuts. Always use new retention hardware.
    Torque spec

    Axle Nut250 Nm (184 lb-ft)
15. 15

    Reinstall wheels and lower vehicle
    Install the rear wheel and thread lug nuts by hand. Torque the lug nuts in a star pattern to specification. Lower the vehicle from jack stands and perform a final torque check on lug nuts with the vehicle on the ground. Remove chocks and perform verification steps.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Ensure all fasteners are torqued to specification in the proper sequence
2. Verify differential fluid level is correct before operation
3. Double-check axle nut retention device is properly installed
4. Inspect for any fluid leaks around the differential cover and axle seal area

Verification

• Test drive the vehicle and listen for any abnormal noises from the rear axle during acceleration and deceleration
• Check for differential fluid leaks around the cover gasket and axle seal after the test drive
• Verify proper axle engagement by confirming no wheel bearing play or axial movement at the hub
• Recheck differential fluid level after test drive and top off if necessary
• Confirm parking brake operation is normal and rear brakes function properly

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