Differential Transfer Shaft: Service and Repair

Side Shaft Gear Assembly-All Wheel Drive (AWD)





Special Tool(s)





Material

Removal

CAUTION: MERCON, MERCON V, MERCON SP, Motorcraft Premium Automatic Transmission Fluid and Motorcraft Continuously Variable Chain Type Transmission Fluid are not interchangeable transmission fluids. The use of any fluid other than what is recommended for this transmission will cause transmission damage.





1. Remove the 2 outer bolts for the driveshaft brace.





2. NOTE: Index-mark the rear driveshaft flange to the power transfer unit (PTU).

NOTE: The driveshaft flange can stay in the power transfer unit (PTU) flange. It does not need to be positioned aside at this time.

Remove and discard the 6 bolts from the front driveshaft flange.
3. Remove the RH halfshaft.





4. Remove and discard the 2 retaining nuts for the front exhaust pipe.





5. Remove and discard the 2 retaining nuts for the rear exhaust nine.





6. Remove and discard the 2 retaining nuts and disconnect the rubber hanger from the catalytic converter pipe.





7. Remove the upper PTU bracket bolts and the bracket.





8. Remove the 4 PTU bolts and the PTU.
9. Using mechanic's wire, position the rear driveshaft aside.





10. Remove the Exhaust Gas Recirculation (EGR) tube.





11. Remove the side shaft gear assembly dust cover.





12. Remove the 4 bolts and remove the side shaft gear assembly.





13. Remove and discard the side shaft gear assembly O-ring seal.

Installation





1. Install a new side shaft gear assembly O-ring ring.





2. Install the side shaft gear assembly bolts.
^ Tighten to 23 Nm (17 ft. lbs.).





3. Using the special tool, install the side shaft gear assembly dust cover.





4. Install the EGR tube.
^ Tighten to 40 Nm (30 ft. lbs.).





5. Position the PTU and the rear driveshaft in place and install the 4 bolts.
^ Tighten to 90 Nm (66 ft. lbs.).





6. Install the upper PTU bracket and bolts.
^ Tighten to 55 Nm (41 ft. lbs.).





7. Install 2 new bolts and connect the rubber hanger for the catalytic converter.
^ Tighten to 40 Nm (30 ft. lbs.).





8. Install 2 new nuts for the rear exhaust pipe.
^ Tighten to 40 Nm (30 ft. lbs.).





9. Install 2 new nuts for the front exhaust pipe.
^ Tighten to 40 Nm (30 ft. lbs.).

10. Install the RH halfshaft.





11. Install the driveshaft cross brace.
^ Tighten to 25 Nm (18 ft. lbs.).





12. NOTE: Align the index-marks made during removal.

NOTE: Use a crisscross pattern to tighten the bolts.

Using new bolts, install the driveshaft flange.
^ Tighten to 25 Nm (18 ft. lbs.).

13. Fill the transaxle with clean CVT automatic transmission fluid. Use the transmission fluid level setting procedure to fill the transaxle.