2003 F-150 Workshop Manual

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Front Drive Axle and Differential

Front Drive Axle, Vacuum Components

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Item 1 2 3 4 5 6 7 8 7G360 4338 19A566

Part Number Vacuum solenoids Upper vacuum lines

Description

Lower vacuum lines/front axle vent tube Front axle actuator motor assy Axle housing vent Auxiliary vacuum reservoir A/C vacuum reservoir tank and bracket Engine vacuum reservoir

Front Axle Assembly Exploded View

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 3A381

Part Number Axle shaft (LH) Snap ring Differential carrier assy Bushing (2 req'd) Fill plug Differential housing cover

Description

N808765-S 3C202 3A443 373098 3N136 390919 390943 F4AZ-19562-B 7G360 3A380 3A379 3B112 4B413 3B210 4338 N808703

Differential housing cover bolt (10 req'd) Magnetic drain plug Gasket (silicone) Front axle actuator motor assy Axle shaft (RH) Axle shaft dust deflector Axle shaft dust seal Axle shaft bearing assy (outer) Axle housing tube (RH) Axle housing vent Axle housing tube bolt (4 req'd)

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2003 F-150 Workshop Manual

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18 19 20 21 22 23 24 25

4121 4B413 3N126 3A392 N808704-S 7W082 7K336

Identification tag Axle shaft bearing assy (inner) Thrust washer (3 req'd) Axle clutch gear E-ring Clutch shaft rod boot Shift lever retaining pin (part of 7K336) Shift lever

Front Differential Exploded View

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

Part Number 389546 4858 4859 3N134 386989 4621 4662 3A443 4616 3A412 3B112 4B413 3N139 7R262 7L253 3N106 7G100 3C211 4631 4628 4630 4663 3N175 4A451 4221 4221 3A397 4205 388056 387426 4230 4215 4211 4236 386984 4224 391583 Pinion nut Axle universal joint flange Drive pinion oil seal deflector Pinion seal Slinger Pinion bearing (outer) Drive pinion collapsible spacer Bushing Pinion bearing cup Differential carrier Driveshaft inner dust seal Axle shaft bearing assy Clutch fork Coupler shift selector gear Axle cluster gear shaft Pilot bearing assy Manual shaft retaining pin Axle shaft shift lever Pinion bearing oil baffle Pinion bearing cup Pinion bearing (inner) Drive pinion bearing adjustment shim Pinion gear Differential bearing shim (2 req'd) Differential bearing cup (2 req'd) Differential bearing (2 req'd) Ring gear Differential case Ring gear bolt (10 req'd) Differential pinion shaft bolt

Description

Differential pinion thrust washer (2 req'd) Differential pinion gear (2 req'd) Differential pinion shaft Differential side gear (2 req'd) Differential side gear thrust washer (2 req'd) Differential bearing cap (2 req'd) Differential bearing cap bolt (4 req'd)

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2003 F-150 Workshop Manual

Page 3 of 3

The axle housing assembly consists of a cast-aluminum center section, a removable cast-aluminum axle housing tube (3B210), and a differential housing cover (3N136). Both the axle housing tube and the differential housing cover use silicone sealant as a gasket. The hypoid-design gearset consists of an 8.8-inch ring gear (3A397) and a pinion gear (3N175). Two opposed tapered roller bearings support the drive pinion in the axle housing. A drive pinion collapsible spacer (4662), located on the pinion shaft, maintains pinion bearing preload. The pinion nut adjusts the preload. Differential bearing shims (4A451), located between the differential bearing cups (4221) and the axle housing, adjust the differential bearing preload and the ring gear backlash. The differential case (4205) is a one-piece design with two openings to allow for assembly of the internal components and lubricant flow. Two opposed tapered roller bearings (differential bearings [4221]) support the differential case in the axle housing. Removable differential bearing caps (4224) retain the differential assembly in the axle housing. Inside the differential case, the differential pinion shaft (4211) supports two differential pinion gears (4215). The pinion gears engage the differential side gears (4236), to which the left axle shaft (3A381) and the axle cluster gear shaft (7L253) are splined. The differential pinion shaft bolt retains the differential pinion shaft in the differential case. An embossed metal tag, bolted to the rear face of the RH axle tube, contains front axle identification information. CAUTION: Actuate the front drive axle with the wheels in a straight ahead position, and at light throttle only. A front axle actuator motor assembly (7G360), controlled by an instrument panel-mounted switch, actuates the front drive axle.

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