Removal and Installation

WARNING: This page is about a different car, the 2005 Mercury Montego, 2005 Ford Freestyle, and 2005 Ford Five Hundred. However, it is still accessible from the selected car via links, so may be relevant.

Remove the driveshaft. For additional information, refer to DRIVESHAFT .
Disconnect the differential electronic module (DEM) by pushing the connector tab through the slot while pulling the connector out.

Fig 1: Disconnecting Differential Electronic Module (DEM)
Courtesy of FORD MOTOR CO.

NOTE: Record the active on-demand coupling bolt locations. The active on-demand coupling bolts vary in length and need to be installed in the correct locations.

NOTE: Completely drain the active on-demand coupling after removal.

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).
  
  Fig 2: Positioning A Drain Pan Under Active On-Demand Coupling
  Courtesy of FORD MOTOR CO.
Clean and inspect the axle assembly cavity for foreign material. Do not use cleaning solvents. Wipe with a lint-free cloth.

Fig 3: Inspecting Axle Assembly Cavity For Foreign Material
Courtesy of FORD MOTOR CO.
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).
  
  Fig 4: Filling New Active On-Demand Coupling
  Courtesy of FORD MOTOR CO.