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Home >> Ford >> 2009 >> Flex Limited, FWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 870 (Front Drive Axle/Differential - DANA 35) >> Removal And Installation >> Axle Assembly >> Removal

Axle Assembly: Removal

WARNING: This page is about a different car, the 2007 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING .
  2. Remove the front wheel and tire assemblies. For additional information, refer to WHEELS AND TIRES .
    3. Fig 1: Locating Caliper Bolts
    GF0009805Courtesy of FORD MOTOR CO.
    WARNING: Remove or tape the brake pads, to prevent them from falling out of the caliper guides.
    CAUTION: Do not allow the calipers to hang by the hoses.
    NOTE: Install a wheel nut to secure each brake disc in place.
  3. Remove the bolts and position both calipers aside.
    • To install, tighten to 33 Nm (24 lb-ft).
    4. Fig 2: Removing Cotter Pin And Nut From Each Tie-Rod End
    GF0009806Courtesy of FORD MOTOR CO.
  4. Remove the cotter pins and nuts from both outer tie rods.
    • To install, tighten to 91 Nm (67 lb-ft).
    5. Fig 3: Separating Tie-Rod Ends From Knuckles Using Special Tool (211-001)
    GF0009807Courtesy of FORD MOTOR CO.
    NOTE: Do not damage the tie-rod dust boots when installing the special tool. Apply a small amount of grease to the tie-rod stud.
  5. Using the special tool, separate the tie-rod ends from the knuckles.
  6. Unclip the left and right wheel anti-lock sensor wiring harnesses from the locators on the vehicle chassis, located above the stabilizer bar brackets.
    7. Fig 4: Locating Upper Ball Joint Bolt
    GF0009808Courtesy of FORD MOTOR CO.
    WARNING: Do not allow the wheel knuckle to hang freely. It is possible to overextend and internally separate the inner CV joint. Separate both axle halfshafts from the front axle.
    CAUTION: Take necessary precautions to protect the machined sealing surfaces on each axle.
  7. Remove both pinch bolts and disconnect the upper ball joints.
    • Pull the RH axle halfshaft, with the wheel knuckle, away from the axle until the axle halfshaft is out of the axle.
    • Pull the LH axle halfshaft, with the wheel knuckle, away from the axle. The LH axle cannot be removed from the axle at this time.
    • To install, tighten to 48 Nm (35 lb-ft).
  8. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING .
  9. Remove the lower engine splash shield, if equipped.
    10. Fig 5: Locating Universal Joint Retainers & Bolts
    GF0009803Courtesy of FORD MOTOR CO.
    WARNING: Tape the U-joint bearing caps to prevent them from falling off the U-joint.
    WARNING: Index-mark the front axle pinion flange to the front driveshaft.
  10. Remove and discard the bolts and straps. Secure the driveshaft aside.
    11. Fig 6: Securing Front Axle Housing To Suitable Jack
    GF0009162Courtesy of FORD MOTOR CO.
    NOTE: Use the Axle Service Plug to plug the axle openings.
  11. Secure the axle housing to a suitable lift.
    12. Fig 7: Locating Bolts (1 Of 2)
    GF0009809Courtesy of FORD MOTOR CO.
  12. Remove and discard the bolts.
    • To install, tighten to 66 Nm (49 lb-ft).
    13. Fig 8: Locating Bolts (2 Of 2)
    GF0009810Courtesy of FORD MOTOR CO.
  13. Lower the axle 25 mm (1 inch) and move to the right 19 mm (0.75 inch), guiding the LH axle halfshaft out of the axle.
    14. Fig 9: Disconnecting Vent Hose From Front Axle Housing
    GF0009811Courtesy of FORD MOTOR CO.
  14. Disconnect the vent hose from the front axle housing.
  15. Lower the axle from the vehicle.
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