Ford Fusion: Rear Drive Halfshafts / Rear Halfshaft. Removal and Installation

Special Tool(s) / General Equipment

	100-001 (T50T-100-A) Slide Hammer
	205-832 Remover, Halfshaft TKIT-2006C-FFMFLM TKIT-2006C-LM TKIT-2006C-ROW

Materials

Removal

NOTICE: Never pick up or hold the halfshaft by only the inner or outer Constant Velocity (CV) joint. Damage to the CV joint will occur.

NOTICE: Never use a hammer to remove or install the halfshafts. Damage to the CV joint may occur.

NOTICE: Never use the halfshaft assembly as a lever to position other components. Damage to the halfshaft or CV joint may occur.

NOTICE: Do not allow the boots to contact sharp edges or hot exhaust components. Damage to the halfshaft boots will occur.

NOTICE: Do not drop assembled halfshafts. The impact may cut the boots from the inside without evidence of external damage.

1. Remove the wheel knuckle.
   Refer to: Wheel Knuckle - AWD (204-02 Rear Suspension, Removal and Installation).
   

1. Using the special tools, remove the rear halfshaft.
   Use Special Service Tool: 205-832  Remover, Halfshaft. , 100-001 (T50T-100-A)  Slide Hammer.

1. 
   Inspect the inner CV joint.
   
   1. Remove and discard the halfshaft retaining circlip.
      
   2. Inspect the halfshaft end for damage.
      

Installation

1. NOTE: The halfshaft seal has to be replaced whenever the halfshaft is removed.

   Replace the rear halfshaft seal.
   Refer to: Rear Halfshaft Seal (205-02 Rear Drive Axle/Differential, Removal and Installation).
   

1. Install the new rear halfshaft retaining circlip.
   

1. NOTE: When seated correctly, the halfshaft retainer circlip can be felt as it snaps into the differential side gear groove.

   Install the rear halfshaft.
   

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)

1. Install the wheel knuckle.
   Refer to: Wheel Knuckle - AWD (204-02 Rear Suspension, Removal and Installation).