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Intermediate Shaft - All Wheel Drive (AWD): Installation

WARNING: This page is about a different car, the 2010 Mercury Milan, 2010 Lincoln MKZ, and 2010 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install a new circlip on the outboard end of the intermediate shaft.
    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: Identifying Axle Retainer Circlip
    G06125776Courtesy of FORD MOTOR CO.
  2. Install a new intermediate shaft seal. For additional information, refer to INSTALLATION .
  3. 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.
  4. Install the 2 intermediate shaft bearing support bolts.
    • Tighten to 40 Nm (30 lb-ft).
  5. Install the RH halfshaft. For additional information, refer to HALFSHAFT .
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