Ford Fusion Manuals

Ford Fusion: Rear Drive Axle/Differential / Axle Assembly. Removal and Installation

Special Tool(s) / General Equipment

Transmission Jack

Materials

Name Specification
Motorcraft® SAE 80W-90 Premium Rear Axle Lubricant
XY-80W90-QL
WSP-M2C197-A
 

Removal

  1. Remove the rear halfshafts.
    Refer to: Rear Halfshaft (205-05 Rear Drive Halfshafts, Removal and Installation).
  1. Remove and discard the driveshaft to rear differential flange bolts and washer assemblies.
    Torque: 26 lb.ft (35 Nm)
Ford Fusion. Axle Assembly. Removal and Installation
  1. NOTE: Do not remove driveshaft from the pinion flange by pulling on the driveshaft tube. Damage to the CV joint can result.


    Disconnect the driveshaft.
    1. Index-mark the driveshaft CV joint coupling and RDU (Rear Drive Unit) flange.
    1. Separate the driveshaft CV joint coupling from the RDU flange.
    1. Position and support the driveshaft aside.
Ford Fusion. Axle Assembly. Removal and Installation
  1. Disconnect the ATC connector.
Ford Fusion. Axle Assembly. Removal and Installation
  1. Disconnect the RDU vent tube.
Ford Fusion. Axle Assembly. Removal and Installation
  1. Position and secure a transmission jack under the RDU.
    Use the General Equipment: Transmission Jack
Ford Fusion. Axle Assembly. Removal and Installation
  1. Remove the rear RDU mounting bolts.
    Torque: 66 lb.ft (90 Nm)
Ford Fusion. Axle Assembly. Removal and Installation
  1. Remove the front RDU mounting bolts and using the transmission jack, remove the RDU.
    Use the General Equipment: Transmission Jack
    Torque: 66 lb.ft (90 Nm)
Ford Fusion. Axle Assembly. Removal and Installation
  1. If installing a new RDU.
    Remove the RDU mounting bracket bolts and mounting brackets.
    Torque: 66 lb.ft (90 Nm)
Ford Fusion. Axle Assembly. Removal and Installation
  1. If installing a new RDU.
    Remove the RDU mounting bracket bolts and mounting brackets.
    Torque: 66 lb.ft (90 Nm)
Ford Fusion. Axle Assembly. Removal and Installation

Installation

  1. NOTICE: If replacing the axle assembly, 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.

    If installing a new RDU, re-configure the Active Torque Coupling (ATC).
    Refer to: Four-Wheel Drive Systems (308-07A Four-Wheel Drive Systems, Diagnosis and Testing).
  1. To install, reverse the removal procedure.
  1. If empty, fill the rear axle with 0.55L (1.15 pt) of rear axle lubricant. If fluid level is low, fill to 3-5 mm (0.118-0.196 in) below the bottom of the filler hole and install the filler plug.
    Material: Motorcraft® SAE 80W-90 Premium Rear Axle Lubricant / XY-80W90-QL (WSP-M2C197-A)
    Torque: 21 lb.ft (29 Nm)
Ford Fusion. Axle Assembly. Removal and Installation

    Rear Drive Axle and Differential. Diagnosis and Testing

    Preliminary Inspection Visually inspect the housing, seals, and pinion flange for obvious signs of mechanical damage. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step If the cause is not visually evident, verify the symptom and REFER to Symptom Chart: NVH...

    Rear Halfshaft Seal. Removal and Installation

    Special Tool(s) / General Equipment 205-153 (T80T-4000-W) Handle 205-990Installer, Axle SealTKIT-2012A-FLTKIT-2012A-ROW Materials Name Specification Motorcraft® SAE 80W-90 Premium Rear Axle LubricantXY-80W90-QL WSP-M2C197-A  Removal Remove the rear halfshaft...

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    Ford Fusion 2013–2020 Owners Manual: In California (U.S. Only)


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