Side Shaft Gear Assembly - All Wheel Drive (AWD): 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.

Lubricate the new side shaft gear assembly O-ring with clean CVT automatic transmission fluid and install the O-ring onto the side shaft gear assembly.

Fig 1: Installing O-Ring Onto Side Shaft Gear Assembly
Courtesy of FORD MOTOR CO.
Install the side shaft gear assembly bolts.
- Tighten to 23 Nm (17 lb-ft).
  
  Fig 2: Installing Side Shaft Gear Assembly Bolts
  Courtesy of FORD MOTOR CO.
Using the special tool, install the side shaft gear assembly dust cover.

Fig 3: Installing Side Shaft Gear Assembly Dust Cover
Courtesy of FORD MOTOR CO.
Install the EGR tube.
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 4: Installing EGR Tube
  Courtesy of FORD MOTOR CO.
Wipe off any residual grease or contaminants from the PTU splines.
- Apply a thin, uniform coating of grease to all of the PTU spline surfaces before assembly.
Position the PTU and the rear driveshaft in place and install the 4 bolts.
- Tighten to 90 Nm (66 lb-ft).
  
  Fig 5: Identifying PTU Bolts
  Courtesy of FORD MOTOR CO.
Install the upper PTU bracket and bolts.
- Tighten to 55 Nm (41 lb-ft).
  
  Fig 6: Identifying Upper PTU Bracket Bolts And Bracket
  Courtesy of FORD MOTOR CO.
Install 2 new bolts and connect the rubber hanger for the catalytic converter.
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 7: Identifying Nuts For Catalytic Converter Pipe
  Courtesy of FORD MOTOR CO.
Install 2 new nuts for the rear exhaust pipe.
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 8: Identifying Nuts For Rear Exhaust Pipe
  Courtesy of FORD MOTOR CO.
Install 2 new nuts for the front exhaust pipe.
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 9: Identifying Exhaust Pipe Nuts
  Courtesy of FORD MOTOR CO.
Install the RH halfshaft. For additional information, refer to FRONT DRIVE HALFSHAFTS .
Install the driveshaft cross brace.
- Tighten to 30 Nm (22 lb-ft).
  
  Fig 10: Identifying Driveshaft Cross Brace Mounting Bolts
  Courtesy of FORD MOTOR CO.

NOTE: Align the index marks made during removal.

NOTE: Use a crisscross pattern to tighten the bolts.

Using new bolts, install the driveshaft flange.
- Tighten to 30 Nm (22 lb-ft).
  
  Fig 11: Identifying Driveshaft Flange Bolts
  Courtesy of FORD MOTOR CO.
If required, top off the transaxle with clean CVT automatic transmission fluid. Use the transmission fluid level setting procedure to fill the transaxle. For additional information, refer to TRANSMISSION FLUID LEVEL CHECK AND SETTING .