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

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

CAUTION: MERCON®, MERCON®V, MERCON®SP, Motorcraft Premium Automatic Transmission Fluid and Motorcraft Continuously Variable Chain Type Transmission Fluid are not interchangeable transmission fluids. The use of any fluid other than what is recommended for this transmission will cause transmission damage.

Remove the 2 outer bolts for the driveshaft brace.

Fig 1: Removing Driveshaft Brace Bolts
Courtesy of FORD MOTOR CO.

NOTE: Index-mark the rear driveshaft flange to the power transfer unit (PTU).

NOTE: The driveshaft flange can stay in the power transfer unit (PTU) flange. It does not need to be positioned aside at this time.

Fig 2: Identifying Driveshaft Flange Bolts

Courtesy of FORD MOTOR CO.

Remove and discard the 6 bolts from the front driveshaft flange.
Remove the RH halfshaft. For additional information, refer to FRONT DRIVE HALFSHAFTS .
Remove and discard the 2 retaining nuts for the front exhaust pipe.

Fig 3: Identifying Exhaust Pipe Nuts
Courtesy of FORD MOTOR CO.
Remove and discard the 2 retaining nuts for the rear exhaust pipe.

Fig 4: Identifying Nuts For Rear Exhaust Pipe
Courtesy of FORD MOTOR CO.
Remove and discard the 2 retaining nuts and disconnect the rubber hanger from the catalytic converter pipe.

Fig 5: Identifying Nuts For Catalytic Converter Pipe
Courtesy of FORD MOTOR CO.
Remove the upper PTU bracket bolts and the bracket.

Fig 6: Identifying Upper PTU Bracket Bolts And Bracket
Courtesy of FORD MOTOR CO.
Remove the 4 PTU bolts and the PTU.

Fig 7: Identifying PTU Bolts
Courtesy of FORD MOTOR CO.
Using mechanic's wire, position the rear driveshaft aside.
Remove the exhaust gas recirculation (EGR) tube.

Fig 8: Removing Exhaust Gas Recirculation (EGR) Tube
Courtesy of FORD MOTOR CO.
Remove the side shaft gear assembly dust cover.

Fig 9: Removing Side Shaft Gear Assembly Dust Cover
Courtesy of FORD MOTOR CO.
Remove the 4 bolts and remove the side shaft gear assembly.

Fig 10: Removing Bolts And Side Shaft Gear Assembly
Courtesy of FORD MOTOR CO.
Remove and discard the side shaft gear assembly O-ring seal.

Fig 11: Removing Side Shaft Gear Assembly O-Ring Seal
Courtesy of FORD MOTOR CO.
Inspect the side shaft gear assembly for damage. If damage is indicated, install new components. For additional information, refer to SIDE SHAFT GEAR ASSEMBLY .