Axle Shaft - Rear

This procedure covers the removal and replacement of the rear axle shaft on a 2015-2020 Ford F-150 with 5.0L V8 engine and rear-wheel drive configuration.

Warnings

Tools required

Parts

• Rear axle shaft assembly × 1 — Use OEM specification for your specific rear axle ratio
• Axle shaft seal × 1 — Use OEM specification
• Differential cover gasket or RTV sealant × 1 — Motorcraft TA-357 RTV or pre-cut gasket
• C-clip or axle retainer (if equipped) × 1 — Use OEM specification

Fluids

• Motorcraft 75W-140 Synthetic Gear Oil — 2.5 qt

Preparation

1. Park vehicle on level ground and engage parking brake
2. Loosen wheel lug nuts on the rear wheel corresponding to the axle shaft being replaced
3. Raise vehicle and secure on jack stands at frame contact points
4. Remove rear wheel on the side being serviced
5. Place drain pan under rear differential
6. Identify your rear axle type (8.8 inch or 9.75 inch) to ensure correct parts

Procedure

1. 1

   Remove differential cover
   Remove all differential cover bolts in a crisscross pattern. Carefully pry the cover away from the housing using a pry bar at the designated pry points. Allow gear oil to drain completely into the drain pan. Remove the cover and set aside. Note the condition of the drained fluid for metal particles or contamination.
   Torque spec

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

   Clean differential housing mating surface
   Use a wire brush and scraper to remove all old gasket material or RTV sealant from both the differential housing and cover mating surfaces. Clean thoroughly with brake cleaner and wipe dry with shop rags. The surface must be completely clean for proper sealing during reassembly.
3. 3

   Remove differential pinion shaft lock bolt
   Locate the differential pinion shaft lock bolt on the face of the ring gear. Using the appropriate socket, remove the lock bolt. Keep this bolt as it will be reused. The bolt threads through the differential case and retains the pinion shaft.
4. 4

   Remove differential pinion shaft
   Carefully slide the differential pinion shaft out of the differential case. You may need to rotate the driveshaft slightly to align the shaft for removal. Set the shaft aside in a clean area. Do not lose the pinion gears or thrust washers.
   ⚠Keep track of pinion gear orientation and thrust washer position for proper reassembly.
5. 5

   Remove axle shaft C-clip
   Push the axle shaft inward toward the center of the differential to expose the C-clip groove. Using a magnetic pick or small screwdriver, remove the C-clip from the inner end of the axle shaft. The C-clip sits in a groove on the axle shaft and retains it in the differential.
   ⚠C-clips can be easily dropped into the differential housing. Use a magnetic tool and work carefully to avoid losing it.
6. 6

   Remove axle shaft from housing
   Carefully pull the axle shaft straight out of the axle housing tube. The shaft should slide out with moderate effort. If the shaft is stuck, attach a slide hammer with axle puller adapter to the axle flange and use controlled force to extract it. Guide the shaft carefully to avoid damaging the axle seal as it exits.
   ⚠The axle shaft weighs approximately 15-20 pounds. Support it as you remove it to prevent dropping.
7. 7

   Remove and inspect axle seal
   Using a seal puller or pry bar, carefully remove the axle seal from the axle housing tube. Inspect the seal bore for any damage, scoring, or corrosion that could cause the new seal to leak. Clean the seal bore thoroughly with brake cleaner.
8. 8

   Inspect axle shaft and bearings
   Thoroughly inspect the removed axle shaft for wear, damage, or bending. Check the bearing surface for scoring or pitting. Inspect the splines for wear or damage. If replacing only the shaft due to bearing failure, ensure the bearing race in the housing is also removed and replaced.
9. 9

   Install new axle seal
   Lubricate the new axle seal lip with gear oil. Using a seal driver or large socket matching the seal outer diameter, carefully drive the new seal squarely into the axle housing bore until it seats flush with the housing face. Ensure the seal is not cocked or damaged during installation.
   ⚠Do not strike the seal directly with a hammer. Use a seal driver or appropriately sized socket to prevent seal damage.
10. 10

    Install new axle shaft
    Lubricate the axle shaft seal surface with gear oil. Carefully guide the new or reused axle shaft into the axle housing, taking care not to damage the new seal lip. Push the shaft in until the splined end engages with the differential side gear. Ensure the shaft is fully seated.
11. 11

    Install C-clip and pinion shaft
    Pull the axle shaft outward slightly and install the C-clip into the groove on the inner end of the axle shaft. Push the axle shaft inward to seat the C-clip against the differential side gear. Reinstall the differential pinion shaft through the case and pinion gears, aligning the lock bolt hole. Verify the pinion shaft is fully seated and install the lock bolt finger-tight.
12. 12

    Prepare and install differential cover
    If using a gasket, position it on the differential housing. If using RTV sealant, apply a continuous 3-4mm bead around the cover mounting surface, circling all bolt holes. Position the cover onto the housing and install all cover bolts finger-tight. Tighten bolts in a crisscross pattern to the specified torque.
    ℹ️If using RTV, allow 15-30 minutes cure time before filling with gear oil per manufacturer instructions.
    Torque spec

    Differential Cover Bolts35 Nm (26 lb-ft)
13. 13

    Fill differential with gear oil
    Remove the differential fill plug on the front of the housing. Using a fluid pump or squeeze bottle, fill the differential with Motorcraft 75W-140 Synthetic Gear Oil until it reaches the bottom of the fill hole (fluid should just start to seep out). Install the fill plug and tighten securely. Verify no leaks around the cover.
14. 14

    Reinstall wheel and lower vehicle
    Reinstall the rear wheel and hand-tighten all lug nuts. Lower the vehicle until the tire just contacts the ground. Torque the lug nuts to specification in a star pattern. Fully lower the vehicle and remove jack stands.
    Torque spec

    Wheel Lug Nuts203 Nm (150 lb-ft)

Reassembly

1. Ensure all fasteners are torqued to specification
2. Verify differential is filled to proper level with correct fluid
3. Double-check that the C-clip is properly seated before final reassembly
4. If using RTV sealant, avoid operating the vehicle for the recommended cure time

Verification

• Test drive the vehicle at low speed and listen for unusual noises from the rear differential
• Check for gear oil leaks around the differential cover and axle seal after test drive
• Verify smooth operation with no clicking, grinding, or binding during turns
• Recheck differential fluid level after 50-100 miles of driving

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