Intermediate Shaft - Front Wheel Drive (FWD): Installation

All vehicles 

NOTE: Make sure to install the correct circlip for each application. Failure to use the correct diameter circlip may result in shaft removal concerns or shaft damage during vehicle operation.
Fig 1: Locating Halfshaft Retainer Circlip
Courtesy of FORD MOTOR CO.
1. Install a new circlip on the outboard end of the intermediate shaft.
2. Position the intermediate shaft in the transaxle and engage the intermediate shaft splines with the transaxle side gears. Make sure the circlip is locked in the gear.

   3.0L vehicles 

3. Install the 2 halfshaft support bracket bolts.
   • Tighten to 40 Nm (30 lb-ft).
   Fig 2: Locating Halfshaft Support Bracket Bolts (3.0L Vehicles)

   Courtesy of FORD MOTOR CO.

   3.5L vehicles 

4. Install the 3 halfshaft support bracket bolts.
   • Tighten to 40 Nm (30 lb-ft).
   Fig 3: Locating Halfshaft Support Bracket Bolts (3.5L Vehicles)

   Courtesy of FORD MOTOR CO.
5. Install the catalytic converter support bracket and the 2 nuts.
   • Tighten to 23 Nm (17 lb-ft).
   Fig 4: Locating Catalytic Converter Support Bracket Nuts

   Courtesy of FORD MOTOR CO.
6. Install the 2 catalytic converter bracket bolts.
   • Tighten to 20 Nm (177 lb-in).
   Fig 5: Locating Catalytic Converter Bracket Bolts

   Courtesy of FORD MOTOR CO.

   All vehicles 

7. Install the RH halfshaft. For additional information, refer to HALFSHAFT  in this service information.