Removal and Installation

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

CAUTION: Do not loosen the front axle wheel end nut until after the wheel and tire assembly are removed from the vehicle. Wheel bearing damage will occur if the wheel bearing is unloaded with the weight of the vehicle applied.

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING .
Remove the front wheel and tire assembly. For additional information, refer to WHEELS AND TIRES .
Remove and discard the front axle wheel end nut.
- To install, tighten to 250 Nm (184 lb-ft).
  
  Fig 1: Discarding Front Axle Wheel End Nut
  Courtesy of FORD MOTOR CO.

CAUTION: To prevent damage to the brake hose, do not allow the disc brake caliper to hang suspended from the hose.

Remove the 2 disc brake caliper guide pin bolts and position the disc brake caliper aside.
- To install, tighten to 33 Nm (24 lb-ft).
- Using mechanic's wire, position the disc brake caliper aside.
  
  Fig 2: Tightening Bolt
  Courtesy of FORD MOTOR CO.

CAUTION: Do not use a hammer to separate the outboard CV joint from the hub. Damage to the threads and internal CV joint components can result.

Fig 3: Pressing Outboard CV Joint

Courtesy of FORD MOTOR CO.

Using the special tool, press the outboard CV joint until it is loose in the hub.
Remove the tie-rod nut.
- To install, tighten to 70 Nm (52 lb-ft).
Using the special tool, separate the tie-rod from the knuckle.

Fig 4: Separating Tie-Rod From Knuckle
Courtesy of FORD MOTOR CO.
Remove the stabilizer bar link nut.
- To install, tighten to 25 Nm (18 lb-ft).
Remove the upper ball joint nut.
- To install, tighten to 69 Nm (51 lb-ft).

CAUTION: Do not allow the knuckle to hang freely. It is possible to overextend and internally separate each inner CV joint from its housing.

Fig 5: Disconnecting Upper Ball Joint From Knuckle

Courtesy of FORD MOTOR CO.

Using the special tool, disconnect the upper ball joint from the knuckle.

CAUTION: Do not damage the axle shaft oil seal or the machined sealing surface on the inboard CV joint housing.

NOTE: A circlip retains the inboard CV joint housing to the differential side gear in the axle.

Fig 6: Disengage LH CV Joint Housing From Side Gear

Courtesy of FORD MOTOR CO.

Using the special tool, disengage the LH CV joint housing from the side gear.
Remove the LH halfshaft.

CAUTION: Do not damage the axle shaft oil seal, the machined sealing surface on the inboard CV joint housing or the axle shaft splines.

CAUTION: Install a new retainer circlip on the outboard spline end of the axle shaft before reseating the axle shaft in the differential side gear.

Fig 7: Separating Inboard CV Joint Housing From Axle Shaft

Courtesy of FORD MOTOR CO.

Pull the RH halfshaft and the axle shaft away from the axle tube, and separate the inboard CV joint housing from the axle shaft.
Remove the RH halfshaft.

Fig 8: Removing RH Halfshaft
Courtesy of FORD MOTOR CO.

CAUTION: Install and tighten the new axle wheel end nut to specification in a continuous rotation. Stopping the rotation during installation will cause the nylon lock to seat incorrectly. This will cause incorrect torque readings while tightening the axle wheel end nut and lead to bearing failure. Always install a new axle wheel end nut after loosening or when not tightened to specifications in a continuous rotation.

CAUTION: Install a new circlip every time the halfshaft is removed.

NOTE: Start one end of the circlip in the groove and work the circlip over the halfshaft and into the groove to prevent the circlip from overexpanding.

Fig 9: Identifying Circlip Over Halfshaft

Courtesy of FORD MOTOR CO.

To install, reverse the removal procedure.