Ford Fusion: Rear Drive Axle/Differential / Active Torque Coupling Clutch. Removal and Installation

Special Tool(s) / General Equipment

	205-126 (T78P-4851-A) Holding Fixture, Drive Pinion Flange
Tire Lever

Materials

Removal

NOTICE: When replacing the RDU clutch, the ACT coil and yoke are a matched set and must be replaced also.

NOTICE: When replacing the RDU clutch, the 4X4 control module will need to be reconfigured with the new Active Torque Coupling (ATC) bar code information. If the new bar code information does not match the existing 4X4 control module information, driveline damage or driveability concerns can occur.

NOTE: Removal steps may contain installation instructions.

1. Record the number for PCM (powertrain control module) entry before clutch is replaced.
   

1. With the vehicle in NEUTRAL, position it on a hoist.
   Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation).
   

1. Remove the driveshaft.
   Refer to: Rear Driveshaft (205-01 Driveshaft, Removal and Installation).
   

1. Disconnect the Active Torque Coupling (ATC) connector.
   

1. Remove and discard the RDU coupler housing bolts.
   Torque: 30 lb.ft (40 Nm)

1. NOTE: When assembling use a 2 mm bead of silicone sealant.

   NOTE: The RDU coupler housing should be dry. The presence of fluid in the housing cavity is most likely from a failed / overheated Active Torque Coupling (ATC). Clean any fluid from the housing before assembly.

   Using a pry bar, remove the RDU coupler housing.
   Use the General Equipment: Tire Lever
   Material: Motorcraft® Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)

1. Using the special tool, remove and discard the companion flange bolt, remove the companion flange washer and the companion flange.
   Use Special Service Tool: 205-126 (T78P-4851-A)  Holding Fixture, Drive Pinion Flange.
   Torque: 40 lb.ft (54 Nm)

1. Index mark the companion flange and stub shaft.
   

1. Remove the companion flange.
   

1. Remove the RDU clutch coupler housing from the Intelligent Torque Controlled Coupling (ITCC).
   

1. Remove and discard the stub shaft bolts, and remove the stub shaft.
   Torque: 43 lb.ft (58 Nm)

1. Remove and discard the Active Torque Coupling (ATC) coil snap ring.
   

1. NOTE: The ATC coil and the ATC coil yoke must be replaced as a matched set.

   Remove the Active Torque Coupling (ATC) coil.
   

1. NOTE: The ATC coil and the ATC coil yoke must be replaced as a matched set.

   Remove and discard the Active Torque Coupling (ATC) coil yoke bolts and remove the Active Torque Coupling (ATC) coil yoke.
   Torque: 89 lb.in (10 Nm)

1. Clean the mating surface of the RDU differential housing.
   Refer to: RTV Sealing Surface Cleaning and Preparation (303-00 Engine System - General Information, General Procedures).
   

1. Clean the mating surface of the RDU clutch coupler housing.
   Refer to: RTV Sealing Surface Cleaning and Preparation (303-00 Engine System - General Information, General Procedures).
   

Installation

1. Record the etched 4-digit calibration code from the new RDU clutch coupler.
   

1. If the new 4-digit calibration code from the RDU clutch coupler does not match the 4-digit calibration code on the RDU clutch coupler housing, strike out the existing 4-digit calibration code on the RDU clutch coupler housing and write the new 4-digit calibration code with permanent felt tip marker.
   

1. To install, reverse the removal procedure.