ford Workshop Repair Guides

Ford Transit Workshop Service and Auto Repair Manuals

ABOUT US
Disassembly and Assembly > < Differential Case

Transit 20065 Rear Drive Axle-Differential: Removal and Installation

Rear Drive Axle/Differential - Axle Assembly Transit 2006.5 (04/2006-)
Removal and Installation

General Equipment
Brake hose clamp
Trolley jack

Removal

CAUTION:
CAUTION:If brake fluid is spilt on the paintwork, the affected area must be immediately washed down with cold water.
  1. Using a suitable brake hose clamp, clamp the brake hoses.

  1. CAUTION:
    CAUTION:Cap the brake tubes to prevent fluid loss or dirt ingress.
    Disconnect the brake tubes and the axle housing vent.
    1. Disconnect the brake tubes from the brake hose retaining bracket.
    1. Disconnect the rear axle housing vent from the rear axle.

  1. Detach the brake hose retaining bracket from the axle housing.

  1. Loosen the park brake cables.

  1. Detach the rear wheel speed sensors and the parking brake cables on both sides.
  1. Remove the wheel hubs.
    For additional information, refer to: Wheel Hub (205-02B Wheel Hubs and Bearings - Full Floating Axle, Removal and Installation).

  1. Detach the stabiliser connecting rod.

  1. Detach the shock absorbers from the axle housing.

  1. NOTE:
    NOTE:Mark the position of the driveshaft flange in relation to the drive pinion flange.
    Detach the driveshaft from the drive pinion flange and position it to one side.
    • Discard the bolts.

  1. WARNING:
    WARNING:Driveshafts without a sliding joint protective boot must have the rear section of the driveshaft removed to prevent accidental seperation of the sliding joint. Failure to follow this instruction may result in personal injury.
    Remove the rear section of the driveshaft if necessary.

  1. Using a suitable trolley jack, support the axle assembly.

  1. Remove the spring U-bolts.
    • Discard the nuts.
  1. Remove the axle assembly.

Installation
  1. Using a suitable trolley jack, locate the axle assembly under the vehicle.

  1. NOTE:
    NOTE:Final tightening of the rear suspension components should be carried out when the vehicle weight is on the road wheels.
    NOTE:
    NOTE:Install new spring U-bolt nuts.
    NOTE:
    NOTE:Do not fully tighten the spring U-bolt nuts at this stage.
    Install the spring U-bolts.
    1. Locate the spring to the rear axle assembly.
    1. Install the guide plate and U-bolts.
    1. Install the nuts.

  1. Attach the shock absorbers to the axle housing.

  1. Detach the stabiliser connecting rod.

  1. NOTE:
    NOTE:Make sure that the arrows are aligned.
    Install the rear section of the driveshaft if necessary.

  1. CAUTION:
    CAUTION:Install new bolts.
    NOTE:
    NOTE:Align the mark on the driveshaft flange with the mark on the drive pinion flange.
    Attach the driveshaft to the drive pinion flange.
  1. Install the wheel hubs.
    For additional information, refer to: Wheel Hub (205-02B Wheel Hubs and Bearings - Full Floating Axle, Removal and Installation).

  1. Attach the rear wheel speed sensors and the parking brake cables on both sides.

  1. Adjust the parking brake cable.
    For additional information, refer to: Parking Brake Cable Adjustment - Vehicles With: Rear Disc Brakes (206-05A Parking Brake and Actuation, General Procedures).

  1. Attach the brake hose retaining bracket to the axle housing.

  1. Connect the brake tubes to the brake hose retaining bracket and attach the axle housing vent.

  1. Remove the brake hose clamp, from the brake hose.

  1. Tighten the spring U-bolt nuts in the sequence shown in seven stages.
    • Stage 1: Tighten nuts 1 through 4 to 25 Nm.
    • Stage 2: Tighten nuts 1 through 4 to 50 Nm.
    • Stage 3: Tighten nuts 1 through 4 to 75 Nm.
    • Stage 4: Tighten nuts 1 through 4 to 100 Nm.
    • Stage 5: Tighten nuts 1 through 4 to 125 Nm.
    • Stage 6: Tighten nuts 1 through 4 to 150 Nm.
    • Stage 7: Tighten nuts 1 through 4 to 175 Nm.
  1. Bleed the brake system.
    For additional information, refer to: Brake System Bleeding (206-00 Brake System - General Information, General Procedures).

Disassembly and Assembly > < Differential Case