Differential Seals - RH, All Wheel Drive (AWD)

Differential Seals - RH, All Wheel Drive (AWD)

Special Tool(s):

Material:

Removal

CAUTION: MERCON (R), MERCON (R) V, MERCON (R) 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 driveshaft brace outer bolts.





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

NOTE: The driveshaft flange can stay in the 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 pipe.





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. Using the special tools, remove the outer differential fluid seal.





11. Using the special tools, remove the inner differential fluid seal.





Installation
1. Lubricate the new inner seal in clean continuously variable transaxle (CVT) transmission fluid and position the inner seal in place.





2. Using the special tools, install the new inner differential fluid seal.





3. Lubricate the new outer seal in clean CVT transmission fluid and position the outer differential fluid seal in place.





4. Using the special tool, install the outer differential fluid seal.





5. Wipe off any residual grease or contaminants from the PTU splines.
^ Apply a thin, uniform coating of grease to all the PTU spline surfaces before assembly.
6. Position the PTU and the rear driveshaft in place and install the 4 bolts.
^ Tighten to 90 Nm (66 ft. lbs.).





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





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





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





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





11. Install the RH halfshaft.
12. Install the driveshaft cross brace.
^ Tighten to 30 Nm (22 ft. lbs.).





13. 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.).





14. If required, top off the transaxle with clean CVT transmission fluid. Use the transmission fluid level setting procedure to fill the transaxle.