Removal and Installation

Halfshaft





Special Tool(s)

Removal

CAUTION: Do not begin this procedure unless the following parts are available:
^ A new front axle wheel hub retainer.
^ A new nut to retain the knuckle to the strut.
^ A new nut to retain the front suspension lower arm to the ball joint.
^ A new circlip.
Do not reuse these parts during assembly. Their torque retention capability diminishes during removal.

NOTE: This procedure applies to both the LH and RH halfshaft assemblies.

1. Remove the center hub cap from the wheel.





2. Loosen the nut.
3. Raise and support the vehicle.
4. Remove the front wheel and tire assembly.





5. Remove the nut and washer.





6. Remove the front brake anti-lock sensor harness from the clip.





7. Remove and position the front brake anti-lock sensor aside.





8. Remove and discard the nut.





9. Carry out the following:
1. Remove the bolt.
2. Remove the nut and bolt. Discard the nut.





10. Using the special tools, press the ball joint stud until it is loose in the knuckle.





11. WARNING: Wire the knuckle to the strut. This will prevent the knuckle from falling off of the strut while the knuckle and lower ball joint are separated. Failure to follow these instructions may result in personal injury.

NOTE: Failure to reposition the knuckle on the strut body will prevent separation of the front suspension lower arm from the knuckle.

Reposition the knuckle, and secure it to the strut.
1. Pull upward on the knuckle to raise it approximately 12.7 mm (0.5 inch) on the strut body.
2. Wire the knuckle to the strut.





12. Disconnect the front suspension lower arm from the knuckle.





13. CAUTION: Never use a hammer to separate the front wheel driveshaft joint (3B413) from the wheel hub. Damage to the joint threads and internal components can result.

NOTE: Position the Metric Hub Remover opposite the Hub Adapter, and fully thread it on the wheel stud.

Using the special tools, press the front wheel driveshaft joint until it is loose in the wheel hub.





14. CAUTION: Do not allow the halfshaft to hang unsupported. Damage to the CV joints and boots can result.

CAUTION: Do not damage the front wheel driveshaft joint boot or the damps.

Remove the front wheel driveshaft joint from the wheel hub.





15. CAUTION: Do not damage the crank sensor when removing the RH halfshaft assembly.

Using the special tool, separate the inboard CV joint housing assembly from the transaxle.

16. CAUTION: Do not damage the differential seal.

Carefully remove the halfshaft assembly with both hands.

Installation
1. Lubricate the differential seal.
^ Use Ford Synthetic MERCON Multi-Purpose Automatic Transmission Fluid E6AZ-19582-B or equivalent meeting Ford specification ESR-M2C163-A2.





2. CAUTION: Install a new circlip every time you remove the halfshaft from the vehicle.

On the RH side only, install a new circlip.
^ Start one end in the groove and work the circlip over the shaft and into the groove. This will prevent the circlip from over-expanding.





3. CAUTION: Do not damage the inboard CV joint housing assembly and the differential seal.

NOTE: If necessary, use a non-metallic mallet to aid in seating the circlip in the differential side gear groove (RH) or inboard CV joint housing (LH). Tap only on the outboard front wheel driveshaft joint.

Align the inboard CV joint housing splices with the differential side gear splices (RH) or output shaft splices (LH), and push the inboard CV joint housing assembly inward until the circlip seats in the differential side gear (RH) or inboard CV joint housing (LH).





4. Align the front wheel driveshaft joint splines and the wheel hub splices, and push the joint into the wheel hub as far as possible.





5. Connect the suspension lower arm to the knuckle.





6. Using the old nut, seat the front wheel driveshaft joint in the hub. Remove the old nut and discard it.





7. Install a new nut.








8. Carry out the following:
1. Remove the wire.
2. Install the bolt and nut.
3. Position the brake hose bracket and install the bolt.





9. Install the front brake anti-lock sensor.





10. Install the front brake anti-lock sensor harness in the clip.
11. Install the wheel and tire assembly.
12. Lower the vehicle.





13. CAUTION: Install and tighten the new front axle wheel hub retainer to specification in a continuous rotation. Stopping the rotation during installation will cause the nylon lock to set incorrectly. This will cause incorrect torque readings while tightening the retainer, and lead to bearing failure. Install a new front axle wheel hub retainer every time after loosening the retainer or not installing the retainer to specification in a continuous rotation.

Tighten the new nut to specification in a continuous rotation.
14. Check and, if necessary, fill the transaxle to the correct level.