1992 and later crown victorias have a Drum-In-Hat (DIH) emergency brake
setup. Conventional hydraulic braking is accomplished by the brake
caliper clamping the brake rotor between two brake pads. To the surpise
of many crownvic owners, the emergency brake setup is actuated by
expanding a set of minature brake shoes against the inside of the brake
Here is the driver's side rear of a 2005 crown victoria police
interceptor with the following components removed:
-rear axle shaft
Here is the passenger's side of the car
The rear axle bearing on this side was trashed and the e-brake setup is
covered in differential oil as a result.
Here's one of the axle bearings and accompying seals after they have
been pulled out of the rear axle assembly
Here are the axle shafts
The axle shaft acts as an inner race for the bearing. When a bearing
fails, you'll often find a groove worn in the axle shaft where the
bearing rollers ride.
Also note that you'll sometimes need to swap the antilock brake tone
rings from your old axle shafts onto your new axle shafts. Some
aftermarket axle shafts don't come with tone rings at all. Worse yet,
some aftermarket axle shafts (i.e. dorman brand) do come with tone
rings, but they are the wrong size and don't fit properly with the
other rear axle parts.
Here's a closeup of the damage to the axle shaft.
That deep circular goove is not supposed to be there. In an extreme
case of wear like this, you'll want to thoroughly flush all the old oil
out of the differential because it will have metal shavings suspended
in it. If you don't clean out the metal shavings, you'll expierence
multiple repeat failures of the differential parts in the future. Some
people have also suggested replacing all the bearings in the
differential in a case like this because they are likely scored from
being exposed to metal for a while. When cleaning out the differential
housing, pay particular attention to the area where the axle tubes meet
the "pumpkin" that houses the carrier. There is a lip there where
debris collects that is often missed during oil cleaning procedures.
Here's the other end of the axle shafts where they would normally pass
into the differential carrier and have the c-clips installed. 2005
crownvics manufactured after 12/04/2004 have 31-spline axles instead of
the 28-spline axles that
you'll find in earlier vehicles.
Here are some other rear axle parts. Note the C-Clips in the lower
right portion of the picture.
In some of the earlier crownvics, you'll notice differential cover is
constructed of high grade stainless steel that doesn't rust like this.
Here's the other side of the differential. Also shown are the pinion
shaft and accompanying lock bolt. Note that the pinion lock bolt came
out clean in this case and didn't break in half.
Here are the rear brake rotors. Starting in the 2003 model year,
crownvic rear brake rotors received cooling vanes to help dissipate
heat. Prior to the 2003 model year, rear brake rotors were a solid
peice of iron without cooling fins.
Here is the back of the brake rotors showing the surface that the
e-brake shoes would normally lock against.
The pictures below were taken by DetroitP71
www.crownvic.net of his 2005 crown victoria police interceptor
during a rear axle shaft replacement project. As part of this project,
DetroitP71 decided to disassemble the e-brake system and clean the
parts up a little bit.
The circular hole on the on the right where the antilock brake wheel
speed sensor would normally be located. You'll need to remove this
sensor before you can push the axles inwards to remove the axle
c-clips. The shop manual makes rear anti-lock brake sensor
removal sound simple, first remove the retaining bolt, then slide the
antilock brake sensor out of the e-brake backing plate. Those of you in
the salt-belt will often find that you break the abs sensor during
removal, and will need to install a new wheel speed sensor. Ferritic
metal expands when it corrodes causing the wheel speed sensor to become
rust-jacked inside it's mounting hole.
Note: There are two different 2005 crown victorias shown here. The
pictures towards the top of this webpage are of an 05' P71 that lives
in the northeastern united states. The pictures towards the bottom of
this webpage are of an 05' P71 that lives in the midwestern united
Replacement emergency brake shoes & hardware kits for 2003+
crownvics are avaliable
aftermarket. Aftermarket offerings include:
Autozone H7929 Hardware Kit
(Also sold as: Dorman HW7302 Hardware Kit)
Raybestos H7302 Hardware Kit
Raybestos 777PG Parking Brake Shoes
Ford service part diagrams
Ford Service Part Numbers
6W1Z-2B582-C Bracket - Brake Caliper, RH/LH (Brake Shoe Backing Plate)
(Replaces 3W1Z-2B582-AA) (2003-2010)
3W1Z-2A637-AA Lever - Parking Brake RH/LH (2003-2010)
F58Z-2092-A Plug - Inspection Opening (2003-2010)
6L2Z-2041-A Brake Adjuster, Screw Kit (Replaces 1L2Z-2041-AA)
6W1Z-2041-BA Screw - Adjusting, RH/LH (2006-2010)
3W1Z-2A225-AA Drum Brake Spring Kit (2003-2005)
6W1Z-2A225-AA Kit - Retracting Spring, RH/LH (2006-2010)
6W1Z-2N712-A Park Brake, Shoe & Lining Asy: [Kit - Services
RH & LH] (Replaces 3W1Z-2N712-AA & 5W1Z-2N712-A) (2003-2010)
9W1Z-2A815-A Parking Brake Intermediate Cable (Replaces 3W1Z-2A815-AA)
Parking Brake Shoe Linings
6W1Z-2N712-A (Replaces 3W1Z-2N712-AA & 5W1Z-2N712-A) (2003-2010)
Axle Service Part Numbers
3W1Z-4234-A 28-spline axle (manufactured to 12/04/2004) (replaces
3W1Z-4234-JA & 3W1Z-4234-KA & 3W1Z-4234-HA) (2003-2005)
6W1Z-4234-A 31-spline axle (manufactured from 12/04/2004) (replaces
6W1Z-4234-B lincoln towncar limousine limited slip axle (replaces
3W1Z-4234-GA & 3W1Z-4234-LA & 4W1Z-4234-A) (2003-2010)