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Intermediate Shaft - All Wheel Drive (AWD): Installation

WARNING: This page is about a different car, the 2007 Lincoln MKX and 2007 Ford Edge. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install a new 30 mm (1.181 in) circlip on the outboard end of the intermediate shaft.
    2. Fig 1: Identifying Circlip From Intermediate Shaft
    GF0031500Courtesy of FORD MOTOR CO.
  2. Install a new intermediate shaft seal in the power transfer unit (PTU). For additional information, refer to TRANSFER CASE - POWER TRANSFER UNIT (PTU) .
  3. Position the special tool over the halfshaft oil seal.
    4. Fig 2: Identifying Special Tool (205-816)
    GF0024610Courtesy of FORD MOTOR CO.
  4. 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.
  5. Install the 2 intermediate shaft support bracket bolts.
    • Tighten to 40 Nm (30 lb-ft).
  6. Install the right halfshaft. For additional information, refer to Halfshaft - RH .
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