Ford Explorer: Front Drive Axle/Differential / Removal and Installation - Axle Assembly

Materials

Removal

1. Drain the front differential fluid.
   Refer to: Differential Draining and Filling (205-03 Front Drive Axle/Differential, General Procedures).
   

1. Remove the front RH halfshaft only.
   Refer to: Halfshaft (205-04 Front Drive Halfshafts, Removal and Installation).
   

1. Remove the engine mount RH.
   Refer to: Engine Mount RH (303-01 Engine) .
   Refer to: Engine Mount RH (303-01B Engine - 3.0L EcoBoost, Removal and Installation).
   Refer to: Engine Mount RH (303-01C Engine - 3.3L Duratec-V6, Removal and Installation).
   Refer to: Engine Mount RH (303-01D Engine - 3.3L Duratec-V6 – Hybrid (BP), Removal and Installation).
   

1. Disconnect the front drive axle speed sensor electrical connector and position the wiring harness aside.
   

1. Disconnect the tie strap, detach and position the front axle breather hose aside.
   

3.0 and 3.0L EcoBoost - Hybrid

1. Remove catalytic converter RH.
   Refer to: Catalytic Converter RH (309-00B Exhaust System - 3.0L EcoBoost, Removal and Installation).
   

1. Remove the fasteners and the heat shield.
   

All vehicles

1. NOTICE: The driveshaft yoke fits tightly on the front axle pinion stem with circlip. Never hammer on the driveshaft or any of its components to disengage the driveshaft yoke from front axle pinion stem. Pry only in the area shown, to disengage the driveshaft yoke from the front axle pinion stem or damage to the driveshaft yoke and pinion stem can occur.

   NOTE: Care should be taken not to damage the driveshaft splines.

   Use pry tool to disengage circlip that holds the front driveshaft plug-on yoke to the front axle pinion stem.
   

1. 1. Remove and discard the front axle assembly bolts.
      
   2. Remove the front axle assembly.
      
   3. Gently pull axle and support the front driveshaft.
      

1. Remove and discard the front axle pinion stem circlip.
   

1. Remove and discard the O-ring.
   

Installation

All vehicles

1. NOTE: Make sure that the surface is clean and free of foreign material.

   Clean and inspect the O-ring mating surface.
   

1. NOTE: Make sure that a new O-ring seal is installed.

   Install a new O-ring.
   

1. NOTE: Make sure that the mating surface and the bore is free of corrosion and foreign material, avoid particles getting into the bore.

   Clean and inspect the engine oil pan at front axle assembly mating surface.
   

1. NOTE: Make sure that the mating faces are clean and free of foreign material.

   Clean the debris or contamination of the splines, circlip groove and the surface near the O-ring groove.
   

1. NOTICE: The circlip must be side-loaded on to the front axle pinion stem to prevent deformation of the circlip.

   NOTE: Make sure that the circlip is seated correctly.

   Install the new front axle pinion stem circlip.
   

1. NOTICE: The circlip must be side-loaded on to the front axle pinion stem to prevent deformation of the circlip.

   Lubricate the front driveshaft plug-on yoke splines with grease.
   Material: Slip Yoke Grease / 5L3Z-19A506-A

1. NOTE: Make sure that new bolts are installed.

   
   
   1. Align the front driveshaft to the front axle stem.
      
   2. Install the front axle assembly and the new bolts.
      Torque: 66 lb.ft (90 Nm)
   3. Push the front driveshaft to fit correctly.
      

1. NOTE: Maintain the suitable possible distance between components.

   Ensure the distance between the edge of plug-on yoke and the front axle pinion nut.
   

1. Attach the front axle breather hose and the tie strap.
   

1. Connect the front drive axle speed sensor electrical connector and position the wiring harness with proper routing.
   

3.0 and 3.0L EcoBoost - Hybrid

1. Install the heat shield and fasteners.
   Torque: 89 lb.in (10 Nm)

1. Install catalytic converter RH.
   Refer to: Catalytic Converter RH (309-00B Exhaust System - 3.0L EcoBoost, Removal and Installation).
   

All vehicles

1. Install the engine mount RH.
   Refer to: Engine Mount RH (303-01 Engine) .
   Refer to: Engine Mount RH (303-01B Engine - 3.0L EcoBoost, Removal and Installation).
   Refer to: Engine Mount RH (303-01C Engine - 3.3L Duratec-V6, Removal and Installation).
   Refer to: Engine Mount RH (303-01D Engine - 3.3L Duratec-V6 – Hybrid (BP), Removal and Installation).
   

1. Install the front RH halfshaft.
   Refer to: Halfshaft (205-04 Front Drive Halfshafts, Removal and Installation).
   

1. Fill the front differential with clean fluid.
   Refer to: Differential Draining and Filling (205-03 Front Drive Axle/Differential, General Procedures).