Intermediate Shaft - All Wheel Drive (AWD): Removal

WARNING: This page is about a different car, the 2011 Mercury Milan, 2011 Lincoln MKZ, and 2011 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 TRANSFER CASE - POWER TRANSFER UNIT (PTU) -- FUSION & MILAN article.

Remove the RH halfshaft. For additional information, refer to HALFSHAFT in this service information.
Remove the 2 intermediate shaft bearing support bolts.

Fig 1: Locating Intermediate Shaft Bearing Support Bolts
Courtesy of FORD MOTOR CO.

NOTE: Do not damage the transaxle seals when removing the intermediate shaft.

Carefully remove the intermediate shaft while supporting both ends of the intermediate shaft.
Remove and discard the circlip from the outboard end of the intermediate shaft.

Fig 2: Locating Intermediate Shaft Circlip
Courtesy of FORD MOTOR CO.