Axle will not come out of the axle housing - Trooper Isuzu Cars & Trucks

On a 2001 Jeep Cherokee Sport (XJ), there are typically two speed sensors: the vehicle speed sensor (VSS) and the rear axle speed sensor. The VSS is located on the transmission or transfer case, while the rear axle speed sensor is located on the rear differential housing. Here are some tips to locate the rear axle speed sensor: 1. Locate the rear differential housing: The rear differential is typically positioned towards the rear of the vehicle, underneath the rear cargo area. Look for the large metal housing connected to the rear axle. 2. Identify the speed sensor: The rear axle speed sensor is usually mounted on the differential housing itself. It will have a wiring harness connected to it. 3. Follow the wiring harness: Trace the wiring harness from the rear axle speed sensor. It will lead you to a connector that is plugged into the vehicle's wiring system. The connector may be located near the rear axle or along the frame. 4. Inspect the differential housing: Look closely at the differential housing for a small protrusion with a threaded hole. This is where the rear axle speed sensor is installed. It may have a retaining bolt securing it in place.

Special Tools

• Slide Hammer
• Axle Remover

Removal Procedure

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
3. Remove the brake caliper. Refer to Rear Brake Caliper Replacement.
4. Remove the rear wheel speed sensor. Refer to Rear Wheel Speed Sensor Replacement.
5. Remove the rear axle housing cover and the gasket. Refer to Rear Axle Housing Cover and Gasket Replacement.
6. Remove the pinion shaft locking bolt.


7. On axles without a locking differential, remove the pinion shaft.


8. On axles with a locking differential, remove the shaft part way. Rotate the case until the pinion shaft touches the housing.


9. On axles with a locking differential, use a screwdriver, or a similar tool, in order to enter the differential case and rotate the C-lock?(1) until the C-lock aligns with the thrust block?(2).
10. Push the flange of the axle shaft?(1) toward the differential.


11. Remove the C-lock from the button end of the axle shaft.

Note: When removing the axle shaft, do not rotate the shaft. Rotating the shaft will misalign the gears. Misaligning the gears will make the installing of the axle shaft difficult.
12. Remove the axle shaft from the housing.
13. Hope this helps?

would be nice to know what vehicle , make and model you need this information for
if you already have the axle out of the diff housing, just pry the old seal out of the housing and install the new one
no need to remove the axle tube ( diff housing at all)

what about it?

conventional axle or limited slip? Get axle code off door sticker.

SECTION 205-02: Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear 1998 Explorer/Mountaineer Workshop Manual
IN-VEHICLE REPAIR Rear Wheel Bearing and Axle Shaft Oil Seal -4.0L SOHC and 4.0L EI, Conventional
Special Tool(s) Axle Seal Replacer
T83T-1175-A Axle Wheel Bearing Puller
T83T-1225-A Axle Wheel Bearing Replacer
T83T-1225-B Driver Handle
T80T-4000-W Impact Slide Hammer
T50T-100-A
Removal

1. Remove the axle shaft; refer to Axle Shaft in this section.

Axle Shaft Removal

1. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel (1007) and the rear wheel bearings (1225).
   Loosen the lug nuts (1012).
   1. Remove the center cap.
   1. With the weight of the vehicle on the wheels, loosen the lug nuts.

1. Raise and support the vehicle.

1. Remove the wheel and tire assembly.
   1. Remove the lug nuts.
   1. Remove the wheel and tire assembly.

1. Remove the axle housing cover (4033).
   1. Loosen the axle housing cover bolts (4346) and drain the rear axle (4001).
   1. Remove the axle housing cover bolts.
   1. Remove the axle housing cover.

1. Remove the rear disc brake rotors (2C026); refer to Section 206-04 .

1. CAUTION: Once the differential pinion shaft (4211) has been removed, turning the differential case (4204) or an axle shaft (4234) will cause the differential pinion gears (4215) to fall out of the assembly. This could result in chipped or damaged components.
   Remove the differential pinion shaft.
   1. Remove the differential pinion shaft lock bolt.
   1. Remove the differential pinion shaft.

1. CAUTION: Do not damage the rubber O-rings in the U-washer grooves.
   Remove the U-washers (4N237).
   1. Push the axle shafts inboard.
   1. Remove the U-washers.

1. Reinstall the differential pinion shaft.
   1. Install the differential pinion shaft.
   1. Install the differential pinion shaft lock bolt finger-tight.

1. CAUTION: Do not damage the inner wheel bearing oil seal (1177).
   Remove the two axle shafts.

Installation

1. Lubricate the lip of the inner wheel bearing oil seal.
   • Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.

1. CAUTION: Once the differential pinion shaft has been removed, turning the differential case or an axle shaft will cause the differential pinion gears to fall out of the assembly. This could result in chipped or damaged components.
   Remove the differential pinion shaft.
   1. Remove the differential pinion shaft lock bolt.
   1. Remove the differential pinion shaft.

1. CAUTION: Do not damage the inner wheel bearing oil seal.
   Install the two axle shafts.

1. CAUTION: Do not damage the rubber O-rings in the U-washer grooves.
   Install the U-washers.
   1. Position the two U-washers on the button end of the axle shafts.
   1. Pull the axle shafts outward.

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

1. Install the rear disc brake rotors; refer to Section 206-04 .

1. Install the axle housing cover and fill the rear axle housing (4010) with 2.4 liters (5.5 pints) of specified lubricant; refer to Axle Housing Cover in this section.

1. WARNING: Always remove any corrosion, dirt or foreign material that may be present on the mounting surfaces of the wheel or the surface of the wheel hub or rear disc brake rotor that contacts the wheel. Installing wheels without proper metal-to-metal contact at the wheel mounting surfaces can cause the lug nut to loosen and the wheel to come off while the vehicle is in motion, causing loss of control.
   Clean the wheel hub and mounting surfaces.

1. Install the tire and wheel assembly.
   1. Position the tire and wheel assembly.
   1. Install the lug nuts and lower the vehicle.
   1. Tighten the lug nuts.
   1. Install the center cap.

1. CAUTION: Never remove the axle shaft oil seal by itself. Always remove the rear wheel bearing and the axle shaft oil seal at the same time.
   NOTE: If the axle shaft oil seal is leaking, the axle housing vent may be plugged with debris.
   Use Impact Slide Hammer and Axle Wheel Bearing Puller to remove the rear wheel bearing and the axle shaft oil seal.

Installation

1. Lubricate the new rear wheel bearing.
   1. Use Thermally Stable Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A.

1. Use Axle Wheel Bearing Replacer with Driver Handle to install the rear wheel bearing.

1. Lubricate the lip of the new axle shaft oil seal.
   • Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.

1. Use Axle Seal Replacer with Driver Handle to install the axle shaft oil seal.

1. Install the axle shaft; refer to Axle Shaft in this section.

Top of Form 1
Raise the vehicle and remove the rear wheels.
Clean all dirt from the housing cover and remove the housing cover to drain the lubricant.
Remove the brake drum.
Rotate the differential case until the differential pinion shaft lockscrew can be removed. Remove the lockscrew and pinion shaft.
Push the axle shafts toward the center of the vehicle and remove the C-locks from the grooves on the axle shafts.
Pull the axle shafts from the housing, being careful not to damage the bearing which remains in the housing.
Inspect the axle shaft bearings and replace any doubtful parts. Whenever the axle shaft is replaced, the bearings should also be replaced.
Remove the axle shaft seal from the bore in the housing, using the button end of the axle shaft.
Remove the axle shaft bearing from the housing. Do not reuse the bearing or the seal.
Check the bearing shoulder in the axle housing for imperfections. These should be corrected with a file or polish.

Axle Housing Assembly Removal & Installation To Remove:
Exploded view of the rear axle mounting

1. Raise and support the rear of the vehicle safely using jackstands under the frame. Position a floor jack or a second set of jackstands to support the rear axle housing. If a floor jack is being used, take care when removing the U-bolts to keep the axle from suddenly dislodging.
2. Remove the rear wheels and drums for clearance and to remove some weight from the axle housing.
3. If equipped, remove the axle vibration dampener.
4. Matchmark and remove the rear driveshaft from the pinion flange. Either remove the shaft completely from the vehicle or support it aside from the undercarriage using safety wire, but DO NOT allow the shaft to hang from the slip joint.
5. Remove the shock absorber-to-axle housing retainers, then swing the shock absorbers away from the axle housing.
6. Disconnect the brake lines from the axle housing clips and the backing plates (wheel cylinders). NOTE: When disconnecting the brake lines from the wheel cylinders, immediately plug or cap the lines to prevent system contamination or excessive fluid loss.
   
7. If applicable, unplug the speed sensor connectors at the junction block.
8. Disconnect the parking brake cable(s).
9. Disconnect the axle housing-to-spring U-bolt nuts, washers. U-bolts and the anchor plates.
10. Remove the vent hose from the top of the axle housing.
11. Remove the axle with the help of an assistant by moving it to clear the leaf spring, or if desired, the leaf springs can be disconnected from the frame at the rear end to lower the axle down and back, but first refer to the leaf spring procedures for information regarding spring installation and removal.

To Install:

1. With the help of an assistant, carefully position the rear axle into the vehicle.
2. Connect the vent hose to the axle housing.
3. Be sure the housing is properly positioned on the leaf spring, then loosely install the U-bolts, anchor plates, washers and nuts.
   • Tighten the U-bolt nuts in a cross pattern to 18 ft. lbs. (25 Nm) to make sure everything is evenly seated. Then tighten the nuts in steps to 41 ft. lbs. (55 Nm) on 1994-95 models or 74 ft. lbs. (100 Nm) on 1996 and later models.
4. Remove the caps from the brakes lines then connect the lines and secure them to the axle housing.
5. If removed, connect the parking brake cable(s).
6. If applicable, attach the speed sensor connectors to the junction block.
7. Align and install the driveshaft assembly. Refer to the procedure earlier in this section for details.
8. Install the shock absorbers to the lower mounts, then tighten the mount nuts.
9. If equipped, install the axle vibration dampener.
10. Install the brake drums and the tire/wheel assemblies.
11. Properly refill the brake master cylinder and bleed the hydraulic brake system.
12. Check the fluid level in the rear axle assembly and add, as necessary. Make sure the vehicle is level when checking and adding fluid.
13. Remove the jackstands and carefully lower the truck.

Removal

1. Raise vehicle and place jackstands under rear frame crossmember. Lower the hoist so that rear axle housing is at suitable working height.
   

1. Remove axle housing cover from rear axle housing and drain lubricant.
   

1. Perform the inspection before disassembly.
   

1. Remove rear wheels, rear disc brake calipers and rear disc brake rotors.
   
2. Working through cover opening, remove differential pinion shaft lock pin and remove differential pinion shaft and differential pinion gears (4215).

NOTE: THIS IS FREE INFORMATION!!!!

1. Remove rear brake anti-lock sensor . Push axle shaft inward until u-washers at button end of the axle shaft are clear of side gear recess.
   

1. CAUTION: Do not damage inner wheel bearing oil seals when removing axle shafts from rear axle housing. In addition, axle shafts should be completely removed from rear axle housing.
   Remove u-washers and pull axle shafts out of the rear axle housing.

-Remove tire and brake drum
-put drain pan under axle housing
-remove rear axle housing cover (10 or 12 bolts)
-turn gear untiil the bolt for cross shaft shows and remov e the bolt
-remove the cross shaft.
-push axle in until you can remove "U" clip from axle and axle will pull out,
Remove seal, you need a pulller to remove axle brg.

Section 05-02A: Axle, Integral Carrier — 8.8-Inch Ring Gear 1994 Town Car, Crown Victoria/Grand Marquis. Workshop Manual REMOVAL AND INSTALLATION Axle Shaft NOTE: Whenever replacing the rear axle lubricant, use Rear Axle Lubricant XY-90-QL (ESP-M2C154-A) or equivalent.
Removal
CAUTION: The rear brake anti-lock sensor must be removed before the axle shafts are removed. The rear brake anti-lock sensor is bolted on the rear disc brake caliper anchor plate.

1. Raise vehicle to desired working height. Refer to Section 00-02 . Remove rear wheel (1007) and tire assembly. Remove rear disc brake calipers (2552) and rear disc brake rotors (2C026) .
   
   
   
   
   

1. Clean all dirt from area of axle housing cover with a wire brush and/or cloth.

1. Drain rear axle lubricant by removing the axle housing cover .

1. Remove differential pinion shaft lock pin and differential pinion shaft .
   
   
   
   

1. Push flanged end of the axle shafts toward the center of the vehicle and remove the rear axle shaft retaining u-washer from the button end of the axle shaft .
   
   
   
   

1. Remove axle shaft from the rear axle housing , being careful not to damage the inner wheel bearing oil seal (1177) and rear brake anti-lock sensor ring.

Installation
NOTE: Check for presence of rear axle shaft o-ring (4A332) on the spline end of the shaft and install if not present.
CAUTION: Care must be taken not to let axle shaft splines damage oil seal or bearing assembly.

1. Carefully slide axle shaft into rear axle housing without damaging rear wheel bearing (1225) or rear brake anti-lock sensor indicator (2C189) . Start splines into side gear and push firmly until the button end of axle shaft can be seen in the differential case .

1. Install the rear axle shaft retaining u-washer on the button end of the axle shaft splines, then pull the shaft outboard until the shaft splines engage and the rear axle shaft retaining u-washer seats in the counterbore of the differential side gear .

1. Position the differential pinion shaft through the differential case and differential pinion gears , aligning the hole in the differential pinion shaft with the lock bolt hole. Apply Rear Axle Lubricant to differential pinion shaft lock pin . Install differential pinion shaft lock pin and tighten to 20-41 Nm (15-30 lb-ft). CAUTION: Differential pinion shaft lock pin must be tightened to specification using Stud and Bearing Mount E0AZ-19554-BA (WSK-M2G349-A1) or equivalent.
   
   
   
   
   NOTE: Axle housing cover must be installed within 15 minutes of application of the silicone rubber or new silicone rubber must be applied.
   CAUTION: Make sure machined surfaces on both axle housing cover and rear axle housing are clean before installing the new silicone sealant. Inside of axle must be covered when cleaning the machined surface to prevent axle contamination. Tighten the cover bolts in a crosswise pattern to ensure uniform draw on axle housing cover .
   

1. Apply Silicone Rubber D6AZ-19562-AA or BA (ESB-M4G92-A or ESE-M4G195-A) or equivalent. Install axle housing cover and tighten retaining bolts to 28-38 Nm (38-52 lb-ft).
   
   
   
   

1. Add Motorcraft Rear Axle Lubricant XY-90-QL or KL (ESP-M2C154-A) or equivalent until it is 6-14mm (1/4-9/16 inch) below bottom of fill hole. Add 118.3 mL (4 oz) of Ford Additive Friction Modifier C8AZ-19B546-A (EST-M2C118-A) or equivalent to Traction-Lok axles. Install fill plug and tighten to 20-41 Nm (15-30 lb-ft).

1. Install rear brake anti-lock sensor indicator . Tighten retaining bolt to 4.5-6.8 Nm (40-60 lb-in).

1. Install rear disc brake caliper and rear disc brake rotor .

1. Install wheels and tires.

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1. Insert Rear Bearing Remover T85L-1225-AH in bore and position it behind bearing so tangs on tool engage bearing outer race. Remove rear wheel bearing and inner wheel bearing oil seal as a unit, using Impact Slide Hammer T50T-100-A.
   
   Rear Disc Brake Caliper Anchor Plate
   
   
   
   
   

1. Lubricate the rear wheel bearing with Rear Axle Lubricant.
   
   
   
   

1. Install rear wheel bearing into the housing bore using Axle Tube Bearing Replacer T78P-1225-A.
   
   
   
   CAUTION: Installation of rear wheel bearing or inner wheel bearing oil seal assembly without proper tool may result in an early bearing or seal failure. If inner wheel bearing oil seal becomes cocked in bore during installation, remove it and install a new one.
   

1. Install the inner wheel bearing oil seal using Axle Tube Seal Replacer T78P-1177-A. Use Premium Long-Life Grease XG-1-C or K (ESA-M1C75-B) or equivalent between the lips of the inner wheel bearing oil seal .
   
   
   
   

1. Install axle shafts as outlined.

1. Raise and support vehicle. Ensure that the transmission is in neutral.
2. Remove wheel and tire assembly.
3. Remove brake drum. Refer toBrakes, for proper procedure.
4. Clean all foreign material from housing cover area.
5. Loosen housing cover bolts. Drain lubricant from the housing and axle shaft tubes. Remove housing cover.
6. Rotate differential case so that pinion mate gear shaft lock screw is accessible. Remove lock screw and pinion mate gear shaft from differential case
7. Push axle shaft inward and remove axle shaft C - clip lock from the axle shaft
8. Remove axle shaft. Use care to prevent damage to axle shaft bearing and seal, which will remain in axle shaft tube.
9. Inspect axle shaft seal for leakage or damage.
10. Inspect roller bearing contact surface on axle shaft for signs of brinelling, galling and pitting. If any of these conditions exist, the axle shaft and/or bearing and seal must be replaced