Ford F150 Pickup. Manual — part 509

Fig. 16: Pulling Axle Shafts Outward
Courtesy of FORD MOTOR CO.

3. Install the U-washers.

1. Position the two U-washers on the button ends of the axle shafts.

2. Pull the axle shafts outward.

NOTE:

If a new pinion shaft lock bolt is unavailable, coat the threads with
threadlock.

2003 Ford Pickup F150

2003 DRIVELINE/AXLES Rear Drive Axle/Differential - Ford 10.25-inch - F150 Pickup

Fig. 17: Installing Differential Pinion Shaft & Lock Bolt
Courtesy of FORD MOTOR CO.

4. Install the differential pinion shaft.

1. Align the hole in the differential pinion shaft with the case lock bolt hole.

2. Install a new differential pinion shaft lock bolt.

5. Install the brake discs and calipers.

6. Install the differential housing cover and fill the rear axle housing with the specified type and amount of

rear axle lubricant. For additional information, refer to DIFFERENTIAL HOUSING COVER .

7. Clean the wheel hub and mounting surfaces.

8. Install the tire and wheel assembly. For additional information, refer to WHEELS & TIRES .

WARNING:

Always remove any corrosion, dirt or foreign material on the
mounting surfaces of the wheel (1007) or the surface of the wheel
hub or brake disc that contacts the wheel. Installing wheels without
proper metal-to-metal contact at the wheel mounting surfaces can
cause the lug nut (1012) to loosen and the wheel to come off while
the vehicle is in motion, causing loss of control.

2003 Ford Pickup F150

2003 DRIVELINE/AXLES Rear Drive Axle/Differential - Ford 10.25-inch - F150 Pickup

AXLE SHAFT - DRUM BRAKE

Material

Fig. 18: Material Specification
Courtesy of FORD MOTOR CO.

Removal

1. Raise and support the vehicle.

2. Remove the wheel and tire assembly.

3. Remove the differential housing cover.

z

Drain the lubricant. For additional information, refer to DIFFERENTIAL HOUSING COVER .

4. Remove the rear brake drums. For additional information, refer to DISC - BLACKWOOD, F150

HERITAGE PICKUP & F150 PICKUP .

5. Remove the differential pinion shaft.

1. Remove the differential pinion shaft lock bolt.

2003 Ford Pickup F150

2003 DRIVELINE/AXLES Rear Drive Axle/Differential - Ford 10.25-inch - F150 Pickup

2. Remove the differential pinion shaft.

Fig. 19: Removing Differential Pinion Shaft
Courtesy of FORD MOTOR CO.

CAUTION: Do not damage the rubber O-rings in the U-washer grooves.

2003 Ford Pickup F150

2003 DRIVELINE/AXLES Rear Drive Axle/Differential - Ford 10.25-inch - F150 Pickup