Rear Drive Axle/differential Ford Five Hundred I

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

AXLE ASSEMBLY DESCRIPTION

AXLE ASSEMBLY DESCRIPTION

Rear Drive Axle and Differential

The axle assembly, is driven by the engine through the transaxle to the power take-off (PTO) through the driveshaft to the active on-demand coupling. The differential electronic module (DEM) on the active on-demand coupling regulates how much torque is applied to the axle assembly and half shafts. The DEM monitors front wheel speed and rear wheel speed to determine how much torque (up to 1,000 Nm at the coupling) to apply to the rear wheels. The DEM uses oil pressure via an oil pump and a solenoid to regulate torque through the active on-demand coupling.

The axle assembly uses 2 types of lubricant. In the rear of the axle assembly it uses SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL. In the front of the axle assembly it uses Volvo Transmission Oil 116-1641.

The axle assembly consists of the following components

1. Differential electronic module (DEM)
2. Active on-demand coupling
3. Rear axle housing
4. Rear halfshaft (RH)
5. Rear halfshaft (LH)

Scheme 1

The vehicle certification (VC) label is located in the driver door jamb. The axle code is on the VC label. For additional information on the VC label, refer to IDENTIFICATION CODES .

Refer to DRIVELINE SYSTEM-GENERAL INFORMATION .

Special Tool(s)

SPECIAL TOOL(S) CHART Oil Suction Gun 303-D 104 (D94T-9000-A)

Material

MATERIAL ITEM SPECIFICATION

Scheme 2

Scheme 3

Scheme 4

Scheme 5

1. Remove the driveshaft. For additional information, refer to «DRIVESHAFT»(/ford/five-hundred/i-2004-2007/remont/driveshaft-universal-joints/#driveshaft) .
2. Disconnect the differential electronic module (DEM) by pushing the connector tab through the slot while pulling the connector out.
3. Position a drain pan under the active on-demand coupling. Remove the 4 active on-demand coupling bolts, then separate the active on-demand coupling from the axle assembly. To install, tighten to 27 Nm (20 lb-ft).
4. Clean and inspect the axle assembly cavity for foreign material. Do not use cleaning solvents. Wipe with a lint-free cloth.
5. To install, reverse the removal procedure. Always install a new active on-demand coupling O-ring seal. Using the special tool, fill the active on-demand coupling. Use the specified fluid and fill to the bottom of the fill hole. Tighten to 35 Nm (26 lb-ft).

SPECIAL TOOL(S) CHART Halfshaft Seal Installer 205-814 2-Jaw Puller 205-D072 (D97L-4221-A) or equivalent

Scheme 6

Scheme 7

MATERIAL ITEM SPECIFICATION

Scheme 8

Scheme 9

Scheme 10

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 driveshaft. For additional information, refer to «DRIVESHAFT»(/ford/five-hundred/i-2004-2007/remont/driveshaft-universal-joints/#driveshaft) .
3. Remove and discard the drive pinion flange nut.
4. Using the special tool, remove the drive pinion flange.
5. Remove and, if necessary, discard the drive pinion seal.

Scheme 11

Scheme 12

1. Using the special tool, install a new drive pinion seal.
2. Install the drive pinion flange.
3. Install a new drive pinion flange nut. Tighten to 100 Nm (74 lb-ft).
4. Install the driveshaft assembly. For additional information, refer to «DRIVESHAFT»(/ford/five-hundred/i-2004-2007/remont/driveshaft-universal-joints/#driveshaft) .

SPECIAL TOOL(S) CHART Installer, Drive Pinion Seal 205-812

Scheme 13

Removal

1. Remove the active on-demand coupling. For additional information, refer to «ACTIVE ON-DEMAND COUPLING»(/ford/five-hundred/i-2004-2007/remont/differentials-drive-axles/#rear-drive-axledifferential) .
2. Using a suitable blind hole puller, remove and discard the drive pinion seal.

Installation

1. Using the special tool, install the drive pinion seal.
2. Install the active on-demand coupling. For additional information, refer to «ACTIVE ON-DEMAND COUPLING»(/ford/five-hundred/i-2004-2007/remont/differentials-drive-axles/#rear-drive-axledifferential) .

SPECIAL TOOL(S) CHART Oil Suction Gun 303-D 104 (D94T-9000-A)

MATERIAL ITEM SPECIFICATION

Scheme 14

Scheme 15

1. Remove the drive pinion flange. For additional information, refer to «DRIVE PINION FLANGE AND DRIVE PINION SEAL»(/ford/five-hundred/i-2004-2007/remont/differentials-drive-axles/#rear-drive-axledifferential) .
2. Disconnect the active on-demand coupling oil pump electrical connector.
3. Position a drain pan under the active on-demand coupling.
4. Remove the active on-demand coupling oil pump bolts and the complete active on-demand coupling oil pump body (black pump body and silver flange). To install, tighten to 6 Nm (53 lb-in)
5. To install, reverse the removal procedure. Always install a new active on-demand coupling oil pump seal. Using the special tool, fill the active on-demand coupling. Use the specified fluid and fill to the bottom of the fill hole. Tighten to 35 Nm (26 lb-ft).

SPECIAL TOOL(S) CHART Oil Suction Gun 303-D 104 (D94T-9000-A)

MATERIAL ITEM SPECIFICATION

Note. If installing new components, there is no reason to remove the seals from the old components.

Note. The differential electronic module (DEM) and solenoid valve are calibrated together and must be installed as a set. If installing a new DEM or solenoid valve, install them as a set only.

Scheme 16

Scheme 17

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. Disconnect the DEM by pushing the connector tab through the slot while pulling the connector out.
3. Remove the 2 DEM bolts, then remove the DEM, including the solenoid vlave and the oil temperature sensor.
4. Using channel locks, carefully remove the solenoid valve.
5. Remove the oil temperature sensor from the active on-demand coupling if it did not come out when the DEM was removed.

Scheme 18

1. Assemble the DEM as shown.
2. Install the DEM upper bolt and the DEM in the active on-demand coupling cover. Then install the DEM lower bolt. Tighten to 6 Nm (53 lb-in).
3. Connect the DEM electrical connectors.
4. Flash the DEM with the current software, if a new DEM is installed. For additional information, refer to «DRIVELINE SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/axle-shafts/#driveline-system-general-information) .

Scheme 19

Scheme 20

Scheme 21

Scheme 22

Scheme 23

1. Remove the rear half shafts. For additional information, refer to «REAR DRIVE HALFSHAFTS»(/ford/five-hundred/i-2004-2007/remont/axle-shafts/#rear-drive-halfshafts) .
2. Remove the muffler and tailpipe assembly. For additional information, refer to «EXHAUST SYSTEM»(/ford/five-hundred/i-2004-2007/remont/exhaust/#exhaust-system) .
3. Remove and discard the 6 driveshaft bolts. To install, tighten to 27 Nm (20 lb-ft).
4. Disconnect the rear wheel speed sensor electrical connector.
5. Disconnect the rear drive axle electrical connector and remove the harness from the subframe.
6. Remove the 4 retainers holding the sway bar to the subframe and disconnect the sway bar links. Position the sway bar forward.
7. Remove the rear sway bar. For additional information, refer to «REAR SUSPENSION»(/ford/five-hundred/i-2004-2007/remont/suspension-rear/#rear-suspension) . All vehicles
8. Remove the rear subframe cross brace. To install, tighten to 63 Nm (46 lb-ft).
9. Remove the axle front insulator bolt. To install, tighten to 90 Nm (66 lb-ft).
10. Remove the 2 rear axle insulator bolts, then remove the axle assembly. Lower the axle assembly from the rear of the stabilizer bar. The RH rear axle insulator bolt is not removed from the vehicle until the axle assembly is removed. To install, tighten to 110 Nm (81 lb-ft).
11. To install, reverse the removal procedure.

SPECIAL TOOL(S) CHART Remover/Installer, Insulator 205-813

Scheme 24

Scheme 25

1. Remove the axle assembly. For additional information, refer to «AXLE ASSEMBLY»(/ford/five-hundred/i-2004-2007/remont/differentials-drive-axles/#rear-drive-axledifferential) .
2. Using the special tool, remove the rear axle housing support insulator.

Scheme 26

1. Using the special tool, install the rear axle housing support insulator.
2. Install the axle assembly. For additional information, refer to «AXLE ASSEMBLY»(/ford/five-hundred/i-2004-2007/remont/differentials-drive-axles/#rear-drive-axledifferential) .

SPECIAL TOOL(S) CHART Installer, Halfshaft Seal 205-814

Scheme 27

Scheme 28

1. Remove the axle assembly. For additional information, refer to «AXLE ASSEMBLY»(/ford/five-hundred/i-2004-2007/remont/differentials-drive-axles/#rear-drive-axledifferential) .
2. Remove the differential seals.

Scheme 29

1. Using the special tool, install the differential seals.
2. Install the axle assembly. For additional information, refer to «AXLE ASSEMBLY»(/ford/five-hundred/i-2004-2007/remont/differentials-drive-axles/#rear-drive-axledifferential) .

See also:
• IDENTIFICATION CODES
• DRIVELINE SYSTEM-GENERAL INFORMATION
• DRIVESHAFT
• JACKING & LIFTING
• REAR DRIVE HALFSHAFTS
• EXHAUST SYSTEM
• REAR SUSPENSION
• ACTIVE ON-DEMAND COUPLING