This procedure covers the removal and replacement of a rear CV axle on a 2015-2020 Ford F-150 with 3.5L EcoBoost engine and rear-wheel drive configuration.

Warnings

Tools required

Parts

• CV axle assembly (rear) × 1 — Use OEM specification
• Axle nut (new) × 1 — Use OEM specification
• Ball joint nut (if damaged) × 1 — Use OEM specification
• Differential fluid (if needed) × 1 — Motorcraft 75W-140

Fluids

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

Preparation

1. Park vehicle on level ground and engage parking brake
2. Place wheel chocks in front of front wheels
3. Loosen rear wheel lug nuts while vehicle is on the ground (do not remove)
4. If replacing the axle nut with a new one, ensure it is the correct stake-type nut
5. Raise rear of vehicle with floor jack and support securely on jack stands at manufacturer-recommended lift points
6. Remove rear wheel completely
7. Spray penetrating oil on axle nut, ball joint nut, and CV bolts if corrosion is present

Procedure

1. 1

   Remove axle nut stake and loosen nut
   Use a chisel or punch to carefully unstake the axle nut collar where it is crimped into the axle shaft groove. Once unstaked, use a 36mm socket and breaker bar to loosen the axle nut. It may be necessary to have an assistant apply the brakes or use a pry bar against the wheel studs to prevent the axle from rotating. Do not fully remove the nut yet.
   Torque spec

   Axle Nut281 Nm (207 lb-ft)
2. 2

   Disconnect lower control arm ball joint
   Locate the lower control arm ball joint connection at the rear knuckle. Remove the ball joint nut completely. Use a ball joint separator tool or pickle fork to separate the ball joint from the knuckle. Apply force carefully to avoid damaging the ball joint boot if reusing components.
   Torque spec

   Ball Joint Nut117 Nm (86 lb-ft)
3. 3

   Support the knuckle assembly
   With the ball joint disconnected, the knuckle and hub assembly will have more freedom of movement. Support the knuckle with a bungee cord or wire to prevent it from hanging and stressing the brake line or ABS sensor wiring. Ensure the brake caliper is not supporting any weight.
4. 4

   Mark and remove inner CV joint bolts
   Position the drain pan under the differential. Use a marker or paint pen to mark the orientation of the CV axle flange to the differential flange for reinstallation reference. Remove the bolts securing the inner CV joint to the differential output flange. There are typically 6 bolts. Be prepared for slight fluid seepage.
   ⚠Differential fluid may drip when the CV joint is separated. Keep drain pan positioned correctly.
   Torque spec

   CV Bolts70 Nm (52 lb-ft)
5. 5

   Remove axle nut and separate outer CV joint
   Now fully remove the previously loosened axle nut from the end of the axle shaft. Carefully pull the knuckle assembly outward while simultaneously pulling the axle shaft out of the hub. The splines may be tight; use a dead blow hammer to tap the end of the axle shaft if needed to break it free from the hub. Do not damage the threads.
6. 6

   Remove CV axle from vehicle
   With both ends disconnected, maneuver the CV axle assembly out from behind the brake assembly and suspension components. You may need to angle or rotate the axle to clear all obstructions. Inspect the old axle for the cause of failure (torn boots, clicking noise, etc.).
7. 7

   Clean mounting surfaces
   Use a wire brush to clean the hub splines, differential flange mating surface, and ball joint taper. Remove any corrosion, dirt, or old thread locker from the axle nut threads on the stub shaft. Inspect the hub bearing for roughness or damage while the axle is out.
8. 8

   Install new CV axle into hub
   Insert the outer CV joint splines into the wheel hub. Align the splines carefully and push the axle into the hub as far as it will go by hand. Install the new axle nut onto the threads and thread it on by hand several turns to hold the axle in place, but do not torque yet.
9. 9

   Connect inner CV joint to differential
   Align the inner CV joint flange with the differential output flange using the alignment marks made during disassembly. Start all CV bolts by hand to ensure proper thread engagement. Tighten the bolts in a star pattern to the specified torque.
   Torque spec

   CV Bolts70 Nm (52 lb-ft)
10. 10

    Reconnect lower control arm ball joint
    Position the lower control arm ball joint stud into the knuckle. Install the ball joint nut and tighten to specification. Ensure the ball joint is fully seated in the taper before final torquing.
    Torque spec

    Ball Joint Nut117 Nm (86 lb-ft)
11. 11

    Torque axle nut and stake
    With the axle fully seated in the hub and the suspension reconnected, torque the axle nut to specification using a torque wrench. Have an assistant apply the brakes or use a suitable method to prevent axle rotation during final torquing. After torquing, use a chisel or punch to stake the nut collar into the axle shaft groove to prevent loosening.
    Torque spec

    Axle Nut281 Nm (207 lb-ft)
12. 12

    Reinstall wheel and lower vehicle
    Mount the rear wheel onto the hub and hand-tighten all lug nuts in a star pattern. Lower the vehicle until the tire just contacts the ground (tire still not supporting full weight). Torque the lug nuts to specification in a star pattern. Fully lower the vehicle and remove jack stands.
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)

Reassembly

1. Double-check that all fasteners are torqued to specification, particularly the axle nut and CV bolts
2. Verify the axle nut has been properly staked to prevent loosening
3. Check differential fluid level and top off with Motorcraft 75W-140 if needed after any fluid loss during axle removal
4. Ensure no tools or parts have been left in the wheel well or suspension area

Verification

• Test drive the vehicle at low speed and listen for clicking or popping noises during turns, which would indicate improper CV joint installation
• Verify smooth operation with no vibration at highway speeds
• Inspect for any differential fluid leaks around the CV joint flange after test drive
• Re-check wheel lug nut torque after 50-100 miles of driving
• Confirm proper operation of ABS system (no warning lights) as the wheel speed sensor may have been disturbed during the repair

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