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Intermediate Shaft - All Wheel Drive (AWD): Removal

WARNING: This page is about a different car, the 2010 Mercury Milan, 2010 Lincoln MKZ, and 2010 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: A new intermediate shaft seal in the Power Transfer Unit (PTU) must be installed whenever the intermediate shaft is removed or damage to the seal may occur. For additional information, refer to REMOVAL .
  1. Remove the RH halfshaft. For additional information, refer to HALFSHAFT .
  2. Remove the 2 intermediate shaft bearing support bolts.
    Fig 1: Locating Intermediate Shaft Bearing Support Bolts
    G06269591Courtesy of FORD MOTOR CO.
  3. Carefully remove the intermediate shaft while supporting both ends of the intermediate shaft.
    NOTE: Do not damage the transaxle seals when removing the intermediate shaft.
  4. Remove and discard the circlip from the outboard end of the intermediate shaft.
Fig 2: Identifying Circlip Over Halfshaft
G06065045Courtesy of FORD MOTOR CO.
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