Rear Drive Axle/differential Ford Taurus X I

Material

Material

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Rear Drive Axle and Differential

The rear drive axle consists of the following components

1. Dished circular flange
2. Full-time fluid drive coupling
3. Aluminum housing with steel housing cover
4. Matched ring and pinion
5. Conventional open differential
6. Rubber bushing isolated mounting points
7. Cover mounted axle vent

The rear drive axle operates as follows

1. The rear axle drive pinion receives power from the engine through the transaxle, power transfer unit (PTU), driveshaft and active torque coupling, and is always engaged.
2. The pinion gear rotates the differential ring gear, which is bolted to the differential case outer flange.
3. Inside the differential case, 2 differential pinion gears are mounted on a differential pinion shaft, which is pinned to the differential case.
4. These differential pinion gears are engaged with the differential side gears to which the halfshafts are splined.
5. The halfshafts are held in the differential case by a driveshaft bearing retainer circlip that is located on the inboard constant velocity (CV) joint stub shaft pilot bearing housing. When each halfshaft is installed, the driveshaft bearing retainer circlip engages a step in the differential side gear.
6. There are no stub shaft bearings in the differential housing.
7. As the differential case turns, it rotates the halfshafts and rear wheels.
8. When it is necessary for one wheel and halfshaft to rotate faster than the other, the faster turning differential side gear causes the differential pinion gears to roll on the slower turning differential side gear. This allows differential action between the 2 halfshafts.
9. The pinion seal and the differential halfshaft seals are the only serviced components of the rear drive axle. If other components of the rear drive axle are worn or damaged, the assembly must be installed new.
10. The active torque coupling is installed new as an assembly with the rear axle.
11. The differential housing cover uses a silicone sealant rather than a gasket.

Refer to DRIVELINE SYSTEM - GENERAL INFORMATION article.

Drive Pinion Seal

Special Tools Illustration Tool Name Tool Number Remover, Torque Converter Fluid Seal 307-309 (T94P-77001-BH) Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A) Pinion Seal Replacer 205-133 (T79P-4676-A) Slide Hammer 100-001 (T50T-100-A) 2-Jaw Puller 205-D072 (D97L-4221-A) or equivalent

Scheme 1

Scheme 2

Material

REMOVAL

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/taurus-x/i-2007-2009/remont/hoistjack/#jacking-and-lifting) article.
2. Remove the 3 bolt and washer assemblies and discard.
3. Using the special tool, hold the pinion flange and remove the nut. Discard the nut.
4. Index-mark the location of the pinion to the yoke.
5. Using the special tool, remove the pinion flange.
6. Using the special tool, remove the seal.

INSTALLATION

1. Using the special tool, install the seal.
2. Line up the index marks and position the pinion flange.
3. Using the special tool, install the new pinion nut. Tighten to 244 Nm (180 lb-ft).
4. Position the rear driveshaft constant velocity (CV) joint. Install the 3 new bolt and washer assemblies. Tighten to 25 Nm (18 lb-ft).

Stub Shaft Seal

Special Tools Illustration Tool Name Tool Number Adapter for 303-224 (Handle) 205-153 (T80T-4000-W) Installer, Front Axle Oil Seal 205-350 (T95T-3010-A) Remover, Torque Converter Fluid Seal 307-309 (T94P-77001-BH) Slide Hammer 100-001 (T50T-100-A)

Material

Note. The rear drive unit (RDU) does not have stub shaft pilot bearings. It has stub shaft seals only.

1. Remove the halfshaft assembly. For additional information, refer to «REAR DRIVE HALFSHAFTS»(/ford/taurus-x/i-2007-2009/remont/axle-shafts/#rear-drive-halfshafts) article.
2. Using the special tools, remove the stub shaft seal.

1. Using the special tools, install the stub shaft pilot bearing housing seal.
2. Install the halfshaft assembly. For additional information, refer to «REAR DRIVE HALFSHAFTS»(/ford/taurus-x/i-2007-2009/remont/axle-shafts/#rear-drive-halfshafts) article.

Differential Housing Cover

Material

Scheme 3

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/taurus-x/i-2007-2009/remont/hoistjack/#jacking-and-lifting) article.
2. Remove the 10 bolts and the rear differential cover. Drain the differential fluid from the housing.

1. Clean the gasket mating surfaces of the differential housing and the differential housing cover.
2. Apply a new continuous bead of clear silicone rubber as shown in the illustration.
3. Install the differential housing cover and the 10 bolts. Tighten to 23 Nm (17 lb-ft).
4. Remove the filler plug and fill the rear axle with 1.15L (2.43 pt) of rear axle lubricant, 3-5 mm (0.118-0.196 in) below the bottom of the filler hole. Install the filler plug. Tighten to 29 Nm (21 lb-ft).

Scheme 4

REMOVAL AND INSTALLATION

Note. The rear stabilizer bar and cross bar brace have been removed for illustration clarity only.

1. Remove the spare tire.
2. Remove the rear driveshaft assembly. For additional information, refer to «DRIVESHAFT»(/ford/taurus-x/i-2007-2009/remont/driveshaft-universal-joints/#driveshaft) article.
3. Remove the rear halfshafts. For additional information, refer to «REAR DRIVE HALFSHAFTS»(/ford/taurus-x/i-2007-2009/remont/axle-shafts/#rear-drive-halfshafts) article.
4. Position a suitable transmission hydraulic jack to the axle housing. Securely strap the jack to the housing.
5. Disconnect the active torque coupling electrical connector.
6. Remove the 4 differential housing-to-front insulator bracket bolts. To install, tighten to 90 Nm (66 lb-ft).
7. Remove the 6 side insulator bracket-to-rear axle differential bolts and the axle assembly. To install, tighten to 90 Nm (66 lb-ft).
8. To install, reverse the removal procedure.

See also:
• DRIVELINE SYSTEM - GENERAL INFORMATION
• JACKING AND LIFTING
• REAR DRIVE HALFSHAFTS
• DRIVESHAFT