This procedure covers the removal and installation of the rear driveshaft on a 2011-2014 Ford F-150 3.5L EcoBoost 4WD, including differential flange and transfer case connections.

Warnings

Tools required

Parts

• Rear driveshaft assembly × 1 — Use OEM specification
• U-joint strap bolts (if damaged) × 4 — M10 x 1.5 flange bolts

Preparation

1. Park vehicle on level surface, engage parking brake, and place transmission in Park
2. Chock front wheels to prevent vehicle movement
3. Raise rear of vehicle using floor jack and support securely on jack stands at frame rails
4. Allow exhaust system to cool completely if vehicle was recently driven
5. Clean area around driveshaft connections to prevent debris from entering differential or transfer case

Procedure

1. 1

   Mark driveshaft alignment
   Using white paint marker or chalk, mark the relationship between the rear driveshaft and the rear differential pinion flange. Also mark the front of the driveshaft to the transfer case output flange. These alignment marks are critical for maintaining driveline balance during reinstallation.
2. 2

   Support the driveshaft
   Position a transmission jack under the center of the driveshaft, or have an assistant ready to support it. The driveshaft will become free once the fasteners are removed and must be controlled to prevent damage to components or injury.
3. 3

   Remove rear U-joint straps
   Remove the four bolts securing the rear U-joint straps to the differential pinion flange. Keep the U-joint caps in place on the yoke as you loosen the bolts. Remove the straps and carefully separate the driveshaft from the pinion flange. You may need to rotate the driveshaft slightly to access all bolts.
4. 4

   Remove front CV joint bolts
   Locate the constant velocity (CV) joint at the front of the driveshaft where it connects to the transfer case output flange. Remove the bolts securing the CV joint flange to the transfer case flange. There are typically 6 bolts. Keep track of any washers or spacers.
   ⚠Some fluid may drip from the transfer case output seal area. Position drain pan if needed.
5. 5

   Remove driveshaft assembly
   With both ends disconnected, carefully lower and slide the driveshaft assembly rearward and downward to remove it from the vehicle. The CV joint end may require slight manipulation to clear the transfer case. Avoid dropping or striking the driveshaft as this can damage the balance or U-joints.
6. 6

   Inspect components
   Inspect the U-joints for wear, binding, or excessive play by attempting to move the joint caps. Check CV joint boot for tears or grease leakage. Inspect the splines on the CV joint and transfer case output for wear or damage. Examine the differential pinion seal for leaks. Replace driveshaft if U-joints show wear or CV boot is damaged.
7. 7

   Clean mating surfaces
   Use wire brush and shop rags to clean the differential pinion flange and transfer case output flange mating surfaces. Remove any rust, dirt, or old thread locker from bolt holes. Ensure surfaces are clean and free of debris for proper seating.
8. 8

   Install driveshaft assembly
   With assistance or using support, lift the driveshaft into position. Start by aligning the front CV joint flange with the transfer case output flange according to your alignment marks. The CV joint end must be positioned first as it has less adjustment range than the rear U-joint.
9. 9

   Install front CV joint bolts
   Install the CV joint flange bolts finger-tight, ensuring the alignment marks match. Once all bolts are started, tighten them in a star pattern to the specified torque of 70 Nm (52 lb-ft). This ensures even clamping force and proper alignment.
10. 10

    Connect rear U-joint
    Align the rear U-joint yoke with the differential pinion flange according to your alignment marks. Position the U-joint caps into the flange yoke grooves. Install the U-joint straps over the caps and start all four bolts finger-tight.
11. 11

    Torque rear U-joint straps
    Tighten the U-joint strap bolts evenly in a cross pattern to the specified torque of 20 Nm (15 lb-ft). Do not overtighten as this can distort the strap and damage the U-joint caps. Verify that the U-joint moves freely after tightening and that caps are properly seated.
12. 12

    Final inspection
    Verify all fasteners are properly torqued. Check that alignment marks are correctly positioned. Manually rotate the driveshaft to ensure it spins freely without binding or interference. Verify no tools or parts were left in the work area.

Reassembly

1. Remove jack stands and carefully lower vehicle to the ground
2. Verify parking brake is released and transmission is in Park
3. If any differential or transfer case fluid was lost, check and top off levels using Motorcraft 75W-140 Synthetic Gear Oil for rear differential or Motorcraft Transfer Case Fluid as needed

Verification

• Start engine and verify no unusual noises or vibrations from driveline
• Test drive vehicle at various speeds (15-30 mph, then highway speeds) to confirm smooth operation without vibration
• Check for leaks at differential pinion seal and transfer case output seal after test drive
• Re-verify all fastener torque values after test drive if any vibration is detected
• Any vibration may indicate misalignment - verify alignment marks are correct and all fasteners are properly torqued

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