Removal And Installation: Halfshaft: Installation

RH and LH halfshafts 

CAUTION: 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 separation during vehicle operation.
1. Install a new circlip.
Fig 1: Locating Intermediate Shaft Circlip
Courtesy of FORD MOTOR CO.

LH halfshaft 

2. Install the Differential Oil Seal Protector.
Fig 2: Identifying Special Tool 205-461
Courtesy of FORD MOTOR CO.
NOTE: The sharp edges on the stub shaft splines can slice or puncture the oil seal. Use care when inserting the stub shaft into the transmission or damage to the seal may occur.
3. Push the stub shaft into the transmission so the circlip locks into the differential side gear.
   • After insertion, pull the halfshaft inner end to make sure the circlip is locked.

RH halfshaft 

4. Align the splines on the RH halfshaft with the intermediate shaft and push the stub shaft in until the circlip locks the shafts together.
   • After insertion, pull the halfshaft inner end to make sure the circlip is locked.

RH and LH halfshafts 

5. Position the damper fork and install a new damper fork-to-front lower arm bolt and flagnut.
   • Tighten to 103 Nm (76 lb-ft).
6. Position the splash shield and install the pin-type retainers.
Fig 3: Locating Pin Type Retainers
Courtesy of FORD MOTOR CO.
7. Insert the halfshaft into the wheel hub.
8. Insert the upper ball joint into the wheel knuckle and install a new nut.
   • Tighten to 48 Nm (35 lb-ft).
9. Position the brake caliper and anchor plate assembly and install the 2 bolts.
   • Tighten to 90 Nm (66 lb-ft).
10. Position the brake flexible hose bracket and install the bolt.
    • Tighten to 23 Nm (17 lb-ft).
11. Position the wheel speed sensor and install the bolt.
    • Tighten to 23 Nm (17 lb-ft).
12. Position the wheel speed sensor harness bracket and install the bolt.
    • Tighten to 23 Nm (17 lb-ft).
13. Using the Halfshaft Installer, seat the halfshaft into the wheel hub.
Fig 4: Identifying Special Tool 204-161
Courtesy of FORD MOTOR CO.
NOTE: Do not tighten the front wheel hub 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.
NOTE: Apply the brake to keep the halfshaft from rotating.
14. Install a new front wheel hub nut
    • Tighten to 255 Nm (185 lb-ft).
15. Stake the new nut in line with the keyway to a recommended minimum depth of 1 mm (0.039 in) below the keyway diameter to engage the locking feature.
Fig 5: Identifying Rear Wheel Hub Nut
Courtesy of FORD MOTOR CO.
16. Install the front tires and wheels. For additional information, refer to WHEELS AND TIRES article.