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Intermediate Shaft Seal and Deflector: Installation

WARNING: This page is about a different car, the 2008 Mercury Sable, 2008 Ford Taurus X, and 2008 Ford Taurus. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: The following illustration shows the correct orientation of the seal components when installed in the vehicle.
Fig 1: View Of Correct Orientation Of Seal Components When Installed In Vehicle
GF0041497Courtesy of FORD MOTOR CO.
Item Part Number Description
1 - Intermediate shaft seal (part of 7275 kit)
2 - Alignment washer (part of 7275 kit)
3 - Seal deflector (part of 7275 kit)
  1. Place the intermediate shaft seal on the PTU Linkshaft Seal Installer and Driver Handle with the spring side facing away from the tool.
    2. Fig 2: Placing Intermediate Shaft Seal On PTU Link Shaft Seal Installer
    GF0041498Courtesy of FORD MOTOR CO.
  2. Using the PTU Linkshaft Seal Installer and Driver Handle, install the intermediate shaft seal.
    3. Fig 3: Installing Intermediate Shaft Seal
    GF0041499Courtesy of FORD MOTOR CO.
  3. Place the alignment washer on the PTU Linkshaft Seal Installer and Driver Handle with the beveled edge (white-striped side) facing towards the tool.
    4. Fig 4: Placing Intermediate Shaft Seal On PTU Link shaft Seal Installer
    GF0041500Courtesy of FORD MOTOR CO.
    NOTE: Do not use force when installing the alignment washer or damage to the washer can occur.
  4. Using the PTU Linkshaft Seal Installer and Driver Handle, install the alignment washer by hand, pushing it in until it bottoms against the seal.
    • When installed, the white-striped side should be facing out.
    5. Fig 5: Installing Intermediate Shaft Seal
    GF0041499Courtesy of FORD MOTOR CO.
    NOTE: Do not overheat (melt) the seal deflector. Monitor the temperature of the deflector with a suitable temperature measuring device, such as a digital temperature laser or infrared thermometer, while heating. Do not allow the temperature to exceed 100°C (212°F). Overheating will damage the deflector. If the deflector is damaged, a new deflector must be used.
    NOTE: Apply a small amount of silicone brake caliper grease and dielectric compound to the inner lip of the deflector where it installs on the tube inside the PTU before heating. This will ease the installation of the deflector.
  5. Position the deflector on the PTU Linkshaft Seal Dust Shield Installer using silicone brake caliper grease and dielectric compound to retain it to the installer. Using a suitable heat gun, heat the deflector to a minimum of 66°C (150°F) and a maximum of 100°C (212°F) by concentrating the heat across the back of the installer while rotating, not directly on the deflector itself.
    • As an alternative method to heating the seal deflector, place the deflector in boiling water for 3 to 5 minutes. Dry off the deflector and install.
    6. Fig 6: Applying Small Amount Of Silicone Brake Caliper Grease & Dielectric Compound To Inner Lip Of Deflector
    GF0041501Courtesy of FORD MOTOR CO.
  6. Install the seal deflector immediately after heating using the PTU Linkshaft Seal Dust Shield Installer and Driver Handle.
    7. Fig 7: Installing Seal Deflector
    GF0041502Courtesy of FORD MOTOR CO.
  7. Make sure the deflector is completely seated all the way around and there are no cracks on the face or inner diameter white-colored tab. The deflector is correctly installed when the face of the deflector is recessed 3-5 mm (0.12-0.20 in) into the pocket all the way around.
    8. Fig 8: Making Sure Deflector Is Completely Seated All The Way Around
    GF0041503Courtesy of FORD MOTOR CO.
    NOTE: A slight effort may be required to fully seat the intermediate and halfshaft assembly as it passes through the alignment washer.
  8. Install the intermediate and halfshaft assembly and the 2 nuts.
    • Tighten to 25 Nm (18 lb-ft).
    9. Fig 9: Bearing Support Nuts
    GF0045767Courtesy of FORD MOTOR CO.
    NOTE: Some residual fluid will collect between the seal and deflector during this repair. This is a normal condition and should not be misinterpreted as a leak after the repair is complete.
  9. Using brake parts cleaner, thoroughly clean the deflector and intermediate shaft area of any residual fluid that may have accumulated during the repair.
  10. Position the halfshaft and ball joint into the wheel knuckle. Install the new ball joint nut.
    • Tighten to 150 Nm (111 lb-ft).
    11. Fig 10: Identifying Ball Joint Nut
    GF0045871Courtesy of FORD MOTOR CO.
  11. Install the RH brake disc. For additional information, refer to FRONT DISC BRAKE article.
    12. NOTE: Do not tighten the halfshaft nut with the vehicle on the ground. The nut must be tightened to specification before the vehicle is lowered onto the wheels. Wheel bearing damage will occur if the wheel bearing is loaded with the weight of the vehicle applied.
  12. Apply the brake to keep the halfshaft from rotating. Using the previously removed wheel hub nut, seat the halfshaft into the front wheel hub.
    • Tighten to 350 Nm (258 lb-ft).
    • Remove and discard the wheel hub nut.
    13. Fig 11: Locating Front Wheel Hub Nut
    GF0029555Courtesy of FORD MOTOR CO.
    NOTE: The wheel hub nut contains a one-time locking chemical that is activated by the heat created when it is tightened. Install and tighten the new wheel hub nut to specification within 5 minutes of starting it on the threads. Always install a new wheel hub nut after loosening or when not tightened within the specified time or damage to the components can occur.
  13. Apply the brake to keep the halfshaft from rotating and install a new wheel hub nut.
    • Tighten to 350 Nm (258 lb-ft).
  14. Install the RH front wheel and tire. For additional information, refer to WHEELS AND TIRES article.
  15. Top off the transmission fluid as necessary.
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