Intermediate Shaft - Front Wheel Drive (FWD): Installation

All vehicles 

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 as new circlip on the outboard end of the intermediate shaft.
Fig 1: Locating Intermediate Shaft Circlip
Courtesy of FORD MOTOR CO.
2. 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.

3.0L vehicles 

3. Install the 2 halfshaft support bracket bolts.
   • Tighten to 40 Nm (30 lb-ft).
Fig 2: Locating Halfshaft Support Bracket Bolts
Courtesy of FORD MOTOR CO.

3.5L vehicles 

4. Install the 3 halfshaft support bracket bolts.
   • Tighten to 40 Nm (30 lb-ft).
Fig 3: Identifying Halfshaft Support Bracket Bolts & Nuts
Courtesy of FORD MOTOR CO.
5. Install the catalytic converter support bracket and the 2 nuts.
   • Tighten to 23 Nm (17 lb-ft).
Fig 4: Identifying Catalytic Converter Support Bracket & Nuts
Courtesy of FORD MOTOR CO.
6. Install the 2 catalytic converter bracket bolts.
   • Tighten to 20 Nm (15 lb-ft).
Fig 5: Identifying Catalytic Converter Bracket Bolts
Courtesy of FORD MOTOR CO.

All vehicles 

7. Install the RH halfshaft. For additional information, refer to HALFSHAFT  in this article.