Ford Fusion: Rear Drive Halfshafts / Rear Drive Halfshafts. Diagnosis and Testing

Ford Fusion 2013–2020 Service Manual / Chassis / Driveline / Rear Drive Halfshafts / Rear Drive Halfshafts. Diagnosis and Testing

Preliminary Inspection

Visually inspect the CV joints, housing, boots, and clamps 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.

Symptom Chart(s)

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.
REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).

Symptom Chart: NVH

Symptom Chart

Condition	Possible Sources	Actions
Driveline clunk - loud clunk when shifting from REVERSE to DRIVE	Damaged or worn Constant Velocity (CV) joints	INSPECT the Constant Velocity (CV) joints for wear or damage. INSTALL a new halfshaft as necessary. REFER to: Rear Halfshaft (205-05 Rear Drive Halfshafts, Removal and Installation).
	Loose hub nut	CHECK the torque on the hub nut. REPLACE the hub nut if the torque is not at specification. For hub nuts. REFER to: Wheel Bearing and Wheel Hub - AWD (204-02 Rear Suspension, Removal and Installation).
Driveline clunk — occurs as the vehicle starts to move forward following a stop	Loose hub nut	CHECK the torque on the hub nut. REPLACE the hub nut if the torque is not at specification. REFER to: Rear Halfshaft (205-05 Rear Drive Halfshafts, Removal and Installation). REFER to: Wheel Bearing and Wheel Hub - AWD (204-02 Rear Suspension, Removal and Installation).
Grunting — normally associated with a shudder experienced during acceleration from a complete stop	Halfshaft Constant Velocity (CV) joint binding	CHECK the outer Constant Velocity (CV) joint for correct seating into the hub. REPAIR as necessary. REFER to: Rear Halfshaft (205-05 Rear Drive Halfshafts, Removal and Installation).
Driveline vibration - occurs at cruising speeds	Binding or damaged Constant Velocity CV joint	CHECK the outer CV joint for correct seating into the hub. REPAIR as necessary. REFER to: Rear Halfshaft (205-05 Rear Drive Halfshafts, Removal and Installation). REFER to: Wheel Bearing and Wheel Hub - AWD (204-02 Rear Suspension, Removal and Installation).

Differential Seals

NOTICE: When installing shafts, do not allow splines to contact seals during installation or damage to the seals may occur.

Halfshaft seals are susceptible to the same types of damage as drive pinion seals if incorrectly installed. The seal bore must be clean and the lip handled carefully to avoid cutting or tearing it. The seal journal surface must be free of nicks, gouges and rough surface texture.

For information on differential seals,
REFER to: Rear Halfshaft Seal (205-02 Rear Drive Axle/Differential, Removal and Installation).

Rear Drive Halfshafts

Rear Halfshaft. Removal and Installation

Special Tool(s) / General Equipment 100-001 (T50T-100-A) Slide Hammer 205-832Remover, HalfshaftTKIT-2006C-FFMFLMTKIT-2006C-LMTKIT-2006C-ROW Materials Name Specification Motorcraft® SAE 80W-90 Premium Rear Axle LubricantXY-80W90-QL WSP-M2C197-A Removal NOTICE: Never pick up or hold the halfshaft by only the inner or outer Constant Velocity (CV) join..

Other information:

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Fuel Quality

Choosing the Right Fuel

Ford Fusion. Fuel Quality

Your vehicle is designed to operate on regular unleaded gasoline with a minimum pump (R+M)/2 octane rating of 87.