Removal and Installation

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 .