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Home >> Ford >> 2010 >> Fusion AWD V6-3.0L >> Repair and Diagnosis >> Transmission and Drivetrain >> Drive Axles, Bearings and Joints >> Axle Shaft Assembly >> Service and Repair >> Front Drive Halfshafts >> Halfshaft

Halfshaft




Halfshaft





Halfshaft (View 1 of 2)

NOTE: LH halfshaft shown, RH similar.











Halfshaft (View 2 of 2)

NOTE: LH halfshaft shown, RH similar.











Removal

NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts.

RH and LH halfshafts

1. Remove the wheel and tire. For additional information, refer to Wheels and Tires.

2. NOTE: Apply the brake to keep the halfshaft from rotating.

Remove and discard the wheel hub nut.

3. Remove wheel speed sensor harness bracket-to-wheel knuckle bolt.

4. Remove the wheel speed sensor bolt and position the wheel speed sensor aside.

5. Remove the brake flexible hose bracket-to-wheel knuckle bolt.

6. WARNING: Do not breathe dust or use compressed air to blow dust from storage containers or friction components. Remove dust using government-approved techniques. Friction component dust may be a cancer and lung disease hazard. Exposure to potentially hazardous components may occur if dusts are created during repair of friction components, such as brake pads and clutch discs. Exposure may also cause irritation to skin, eyes and respiratory tract, and may cause allergic reactions and/or may lead to other chronic health effects. If irritation persists, seek medical attention or advice. Failure to follow these instructions may result in serious personal injury.

NOTICE: Do not allow the brake caliper to hang from the brake hose or damage to the hose can occur.
Remove the 2 brake caliper anchor plate bolts and position the caliper and anchor plate assembly aside.
- Support the caliper using mechanic's wire.

7. Remove and discard the upper ball joint nut.

8. Using the Steering Arm Remover, separate the upper ball joint from the wheel knuckle.





9. Remove and discard the damper fork-to-front lower arm bolt and flagnut.

10. Using the Front Wheel Hub Remover, separate the halfshaft from the wheel hub.





11. Remove the pin-type retainers and position the splash shield aside.





RH halfshaft

12. Use a brass drift to strike the RH halfshaft in the indicated area and separate the RH halfshaft from the intermediate shaft.





LH halfshaft

13. Using the Halfshaft Remover and Slide Hammer, separate the halfshaft from the transmission.





RH and LH halfshafts

14. Position the damper fork and halfshaft forward of the front lower arm and remove the halfshaft.





15. Remove and discard the stub shaft circlip (LH) or the intermediate shaft circlip (RH).

Installation

RH and LH halfshafts

1. NOTICE: Make sure to install the correct circlip for each application. Failure to use the correct diameter circlip may result in shaft removal concerns or shaft damage during vehicle operation.

Install a new circlip.





LH halfshaft

2. Install the Differential Oil Seal Protector.





3. NOTICE: The sharp edges on the stub shaft splines can slice or puncture the oil seal. Use care when inserting the stub shaft into the transmission or damage to the seal may occur.

Push the stub shaft into the transmission so the circlip locks into the differential side gear.

- After insertion, pull the halfshaft inner end to make sure the circlip is locked.

RH halfshaft

4. Align the splines on the RH halfshaft with the intermediate shaft and push the stub shaft in until the circlip locks the shafts together.
- After insertion, pull the halfshaft inner end to make sure the circlip is locked.

RH and LH halfshafts

5. Position the damper fork and install a new damper fork-to-front lower arm bolt and flagnut.
- Tighten to 103 Nm (76 lb-ft).

6. Position the splash shield and install the pin-type retainers.





7. Insert the halfshaft into the wheel hub.

8. Insert the upper ball joint into the wheel knuckle and install a new nut.
- Tighten to 48 Nm (35 lb-ft).

9. Position the brake caliper and anchor plate assembly and install the 2 bolts.
- Tighten to 90 Nm (66 lb-ft).

10. Position the brake flexible hose bracket and install the bolt.
- Tighten to 23 Nm (17 lb-ft).

11. Position the wheel speed sensor and install the bolt.
- Tighten to 23 Nm (17 lb-ft).

12. Position the wheel speed sensor harness bracket and install the bolt.
- Tighten to 23 Nm (17 lb-ft).

13. Using the Halfshaft Installer, seat the halfshaft into the wheel hub.





14. NOTICE: Do not tighten the front wheel hub nut with the vehicle on the ground. The nut must be tightened to specification before the vehicle is lowered onto the wheels. Wheel bearing damage will occur if the wheel bearing is loaded with the weight of the vehicle applied.

NOTE: Apply the brake to keep the halfshaft from rotating.

Install a new front wheel hub nut.

- Tighten to 255 Nm (185 lb-ft).

15. Stake the new nut in line with the keyway to a recommended minimum depth of 1 mm (0.039 in) below the keyway diameter to engage the locking feature.





16. Install the wheel and tire. For additional information, refer to Wheels and Tires.

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