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

WARNING: This page is about a different car, the 2006 Mercury Montego, 2006 Ford Freestyle, and 2006 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: Locating Side Shaft Gear Assembly O-Ring Seal
Courtesy of FORD MOTOR CO.
Install the side shaft gear assembly bolts.
- Tighten to 35 N.m (26 lb-ft).
Fig 2: Locating Side Shaft Gear Assembly Bolts
Courtesy of FORD MOTOR CO.
Using the special tool, install the side shaft gear assembly dust cover.

Fig 3: Locating Special Tool (307-526)
Courtesy of FORD MOTOR CO.
Install the EGR tube.
- Tighten to 40 N.m (30 lb-ft).
Fig 4: Locating 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 N.m (66 lb-ft).
Fig 5: Locating PTU Bolts
Courtesy of FORD MOTOR CO.
Install 2 new bolts and connect the rubber hanger for the catalytic converter.
- Tighten to 40 N.m (30 lb-ft).
Fig 6: Locating Catalytic Converter Bolts
Courtesy of FORD MOTOR CO.
Install 2 new nuts for the rear exhaust pipe.
- Tighten to 40 N.m (30 lb-ft).
Fig 7: Locating Rear Exhaust Pipe Nuts
Courtesy of FORD MOTOR CO.
Install the upper PTU bracket and bolts.
- Tighten to 55 N.m (41 lb-ft).
Fig 8: Locating Upper PTU Bracket Bolts
Courtesy of FORD MOTOR CO.
Install 2 new nuts for the front exhaust pipe.
- Tighten to 40 N.m (30 lb-ft).
Fig 9: Locating Front Exhaust Pipe Nuts
Courtesy of FORD MOTOR CO.
Install the RH halfshaft. For additional information, refer to INSTALLATION .
Install the driveshaft cross brace.
- Tighten to 30 N.m (22 lb-ft).
Fig 10: Locating Driveshaft Cross Brace Bolts
Courtesy of FORD MOTOR CO.

NOTE:

Align the index marks made during removal.
Use a crisscross pattern to tighten the bolts.

Fig 11: Locating Driveshaft Flange Bolts

Courtesy of FORD MOTOR CO.

Using new bolts, install the driveshaft flange.
- Tighten to 25 N.m (18 lb-ft).
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 .