Removal and Installation

WARNING: This page is about a different car, the 2006 Mercury Mariner and 2006 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.

Remove the RH front drive halfshaft. For additional information, refer to HALFSHAFT .
NOTE: If removing the intermediate shaft in order to repair a separate component, it should only be removed as an assembly with the RH front drive halfshaft.
If equipped with a 3.0L engine, remove the generator shield.
Remove the 2 intermediate shaft bearing retainer nuts. To install, tighten to 27 Nm (20 lb-ft).
Remove the intermediate shaft.

NOTE: On All-Wheel Drive (AWD) vehicles, the Power Transfer Unit (PTU) seal must be replaced everytime the intermediate shaft is removed. For additional information, refer to POWER TRANSFER UNIT (PTU)

CAUTION: Make sure to use the special tool when installing the intermediate shaft. Failure to use the special tool may result in transmission oil leaks.

Fig 1: Identifying Special Tool (205-816)

Courtesy of FORD MOTOR CO.

To install, reverse the removal procedure. Apply a thin coat of grease to the splines of the intermediate shaft.
Check and fill the transaxle fluid as necessary. For additional information, refer to AUTOMATIC TRANSAXLE-TRANSMISSION - CD4E or AUTOMATIC TRANSAXLE-TRANSMISSION - ELECTRONICALLY CONTROLLED CONTINUOUSLY VARIABLE TRANSMISSION (ECVT), or MANUAL TRANSAXLE-TRANSMISSION .