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Front Drive Halfshafts Ford Five Hundred I

Axle Shafts 6 illustrations ~890 words

TORQUE SPECIFICATIONS

DescriptionNmLb-ft
Front axle wheel end nut (1)350259
Disc brake caliper anchor bolts10074
Lower ball joint nut8059
Halfshaft bearing nut2720
(1) Install and tighten the new front axle wheel end nut to specification in a continuous rotation. Stopping the rotation during installation will cause the nylon lock to set incorrectly. This will cause incorrect torque readings while tightening the front axle wheel end nut, and lead to bearing failure. Install a new front axle wheel end nut every time after loosening or not installing the front axle wheel end nut to specification in a continuous rotation.
(1)Install and tighten the new front axle wheel end nut to specification in a continuous rotation. Stopping the rotation during installation will cause the nylon lock to set incorrectly. This will cause incorrect torque readings while tightening the front axle wheel end nut, and lead to bearing failure. Install a new front axle wheel end nut every time after loosening or not installing the front axle wheel end nut to specification in a continuous rotation.

TORQUE SPECIFICATIONS

Inboard and outboard CV joints connect to a splined shaft. Driveshaft bearing retainer circlips retain the CV joints to the splined shaft.

On the LH side, a driveshaft bearing retainer circlip retains the splined inboard CV joint to the differential side gear. Install a new circlip every time you remove the half shaft from the vehicle.

A front axle wheel end nut secures the splined outboard CV joint to the wheel hub.

The lubed-for-life CV joints use special CV joint grease. They require no periodic lubrication.

Halfshaft Handling

CAUTIONNever pick up or hold the halfshaft only by the inboard or outboard CV joint.

Handle all halfshaft components carefully during removal and installation.

  1. Do not over-angle the CV joints.
  2. Damage will occur to an assembled inboard CV joint if it is over-plunged outward from the joint housing.
  3. Never use the halfshaft assembly as a lever to position other components. Always support the free end of the halfshaft.
  4. Do not allow the boots to contact sharp edges or hot exhaust components.
  5. Handle the halfshaft only by the interconnecting shaft to avoid potential damage to the CV joints.
  6. Do not drop assembled halfshafts. The impact will cut the boots from the inside without evidence of external damage.
  7. Do not remove the inner CV joint by pulling on the interconnecting shaft.
  8. Inspect all machined surfaces and splines for damage.

Wheel and Tire Balancing, Rear

WARNINGDo not balance the front wheels and tires while mounted on the vehicle. Possible tire disintegration, differential or halfshaft failure can result, causing personal injury or extensive component damage. Use an off-vehicle wheel and tire balancer only.

Hoisting

CAUTIONUse a frame-contact hoist only. Vehicle or component damage can result if other types of hoists are used.

Never raise the vehicle using the halfshafts as lift points.

Towing

Never tow a vehicle using the halfshafts as anchor points for the tow truck cable or chains. Refer to the TOWING MANUAL for correct procedures.

Undercoating and Rustproofing

During undercoating and rustproofing procedures, protect the boots from the coating materials. Foreign materials on the rubber boots will cause extreme advanced wear.

Special Tool(s)

SPECIAL TOOL(S) CHART Remover, Front Wheel Hub 205-D070 (D93P-1175-B) or equivalent Slide Hammer 100-001 (T50T-100-A) Remover, Halfshaft (Plate) 205-290 (T89P-3415-B) (Use with 205-043) Remover, Halfshaft 205-241 (T86P-3514-A)

Scheme 1

Scheme 1: Special Tool(s)
Scheme 1: Special Tool(s)

Scheme 2

Scheme 2
Scheme 2

Scheme 3

Scheme 3: Removal
Scheme 3: Removal

Scheme 4

Scheme 4
Scheme 4

Scheme 5

Scheme 5
Scheme 5
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/five-hundred/i-2004-2007/remont/hoistjack/#jacking-lifting) .
  2. Remove the front axle wheel end nut and washer. Discard the front axle wheel end nut.
  3. remove the disc brake caliper anchor bolts and the disc brake caliper and anchor assembly. Using mechanic's wire, position the disc brake caliper and anchor assembly aside.
  4. Using the special tool, separate the halfshaft from the hub.
  5. Remove and discard the lower ball joint nut, then disconnect the lower control arm.
  6. Separate the halfshaft from the hub.
  7. Using the special tools, carefully remove the halfshaft from the transaxle.
  8. Inspect the halfshaft seal. If necessary, install a new halfshaft seal. For additional information, refer to «AUTOMATIC TRANSAXLE - 6 SPEED»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transaxle-6-speed) . CVT CAUTION: Do not damage the halfshaft seal.
  9. Using the special tools, carefully remove the halfshaft from the transaxle.
  10. Inspect the halfshaft seal. If necessary, install a new halfshaft seal. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - CVT»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) .

Installation

  1. Install a new axle circlip in the groove on the inboard constant velocity (CV) joint stub shaft.
  2. Install the halfshaft.
  3. Install the halfshaft into the hub.
  4. Connect the lower control arm to the knuckle, then install a new ball joint nut. Tighten to 80 Nm (59 lb-ft).
  5. Using the washer and the old front axle wheel end nut, seat the outboard CV joint in the hub. Remove the old front axle wheel end nut and discard it.
  6. Install a new front axle wheel end nut. Tighten to 350 Nm (259 lb-ft).
  7. Install the disc brake caliper and anchor assembly, then install the disc brake caliper anchor bolts. Tighten to 100 Nm (74 lb-ft).

SPECIAL TOOL(S) CHART Remover, Front Wheel Hub 205-D070 (D93P-1175-B) or equivalent

Scheme 6

Scheme 6
Scheme 6
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/five-hundred/i-2004-2007/remont/hoistjack/#jacking-lifting) .
  2. Remove the front axle wheel end nut and washer. Discard the front axle wheel end nut.
  3. Remove the disc brake caliper anchor bolts and the disc brake caliper and anchor assembly. Using mechanic's wire, position the disc brake caliper and anchor assembly aside.
  4. Using the special tool, separate the halfshaft from the hub.
  5. Remove and discard the lower ball joint nut, then disconnect the lower control arm.
  6. Remove the 2 halfshaft bearing nuts.
  7. Remove the halfshaft.
  8. Inspect the halfshaft seal. If necessary, install a new halfshaft seal. For additional information, refer to «TRANSFER CASE - POWER TRANSFER UNIT (PTU)»(/ford/five-hundred/i-2004-2007/remont/transfer-case/#transfer-case-power-transfer-unit-ptu) , «AUTOMATIC TRANSAXLE/TRANSMISSION - CVT»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transmission-cvt) or «AUTOMATIC TRANSAXLE - 6 SPEED»(/ford/five-hundred/i-2004-2007/remont/automatic-trans/#automatic-transaxle-6-speed) .
  1. Install the halfshaft.
  2. Install the halfshaft bearing nuts. Tighten to 27 Nm (20 lb-ft).
  3. Install the halfshaft into the hub.
  4. Connect the lower control arm to the knuckle, then install a new ball joint nut. Tighten to 80 Nm (59 lb-ft).
  5. Using the washer and old front axle wheel end nut, seat the outboard CV joint in the hub. Remove the old front axle wheel end nut and discard it.
  6. Install a new front axle wheel end nut. Tighten to 350 Nm (259 lb-ft).
  7. Install the disc brake caliper and anchor assembly, then install the disc brake caliper anchor bolts. Tighten to 100 Nm (74 lb-ft).

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