Halfshaft SPECIAL SERVICE TOOL(S) REQUIRED

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1 Page 1 of 8 Section 05-04: Halfshaft, Front Wheel 1999 Taurus/Sable Workshop Manual REMOVAL AND INSTALLATION Procedure revision date: 06/25/1998 Halfshaft SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Remover Adapter 211-S211 (T96P-3010-A1) Tie-Rod Remover Adapter (T81P-3504-W) Steering Arm Remover (T64P-3590-F) Front Hub Tool (T81P-1104-C) Hub Adapter (T86P-1104-A1) Metric Hub Remover Set (T83P-1104-BH) Installing Adapter (T81P-1104-A) Removal 1. CAUTION: Do not begin this procedure unless the following parts are available: A new front axle wheel hub retainer. A new front suspension lower arm-to-ball joint nut. A new circlip. Once removed, these parts must not be reused during assembly. Their torque-holding ability or retention capability is diminished during removal. Remove wheelcover or hub cover from wheel and tire assembly. 2. Loosen lug nuts (1012).

2 Page 2 of 8 3. Raise vehicle on a frame contact hoist and remove the wheel and tire assembly. 4. CAUTION: Discard the front axle wheel hub retainer. It is a torque prevailing design and cannot be reused. Remove the front axle wheel hub retainer and washer. Hub Retainer Loosen Hub Retainer Removal

3 Page 3 of 8 5. For SHO only, remove wiring harness from routing clip on front shock absorber (18124). Remove air suspension height sensor (3C034) from height sensor ball studs. Position air suspension height sensor out of way. 6. Remove the front brake anti-lock sensor wire harness from the wire harness retaining clip. 7. Remove the front brake anti-lock sensor and position aside. 8. Remove and discard front suspension lower arm-to-ball joint nut. 9. Using Ball Joint Tool 211-S200 (T96P-3010-A1), Tie-Rod Remover Adapter (T81P-3504-W) and Steering Arm Remover (T64P-3590-F), press lower ball joint from front suspension lower arm (3A052). 10. Separate front suspension lower arm from lower ball joint. 11. CAUTION: Never use a hammer to separate the front wheel driveshaft joint from the hub. Damage to the front wheel driveshaft joint threads and internal components can result. Install Front Hub Tool (T81P-1104-C), Hub Adapter (T86P-1104-A1), Metric Hub Remover Set (T83P-1104-BH) and Installing Adapter (T81P-1104-A). Push front wheel driveshaft joint only to the point that the splines are free in the hub. Remove puller (assembled tools).

Page 4 of 8 12. CAUTION: Do not allow halfshaft to hang unsupported. CAUTION: Do not damage the boots. Remove front wheel driveshaft joint from wheel hub. 13.

4 Page 4 of CAUTION: Do not allow halfshaft to hang unsupported. CAUTION: Do not damage the boots. Remove front wheel driveshaft joint from wheel hub. 13. Using a pry bar, separate inboard CV joint housing from transaxle. 14. CAUTION: Do not damage the differential seal. Carefully remove halfshaft assembly with both hands.

5 Page 5 of 8 Installation 1. Clean seal journal. Polish with fine emery paper if required. 2. CAUTION: DO NOT reuse circlip. A new circlip must be installed each time the halfshaft is removed from the vehicle. NOTE: To correctly install the circlip, start one end in the groove and work the circlip over the shaft and into the groove. This will avoid over-expanding the circlip. On RH side only, install a new circlip on the inboard CV joint housing. 3. CAUTION: Do not damage the differential seal (4B416). NOTE: A non-metallic mallet may be used to aid in seating the circlip into the differential side gear groove. If a mallet is necessary, tap only on the outboard front wheel driveshaft joint. Carefully align splines of inboard CV joint housing with the splines in the differential side gear (4236). Exerting some force, push inboard CV joint housing into differential side gear until the circlip is felt to seat in the differential side gear.

Position lower ball joint into front suspension lower arm. 6. Install and tighten a new front suspension lower arm-to-ball joint nut to 68-92 Nm (50-68 lb-ft). 7.

6 Page 6 of 8 Seating Retainer Clip 4. Carefully align splines of front wheel driveshaft joint (3B413) with splines in wheel hub (2C300) and push the shaft into the wheel hub as far as possible. 5. Position lower ball joint into front suspension lower arm. 6. Install and tighten a new front suspension lower arm-to-ball joint nut to Nm (50-68 lb-ft). 7. CAUTION: Install and tighten the new front axle wheel hub retainer to specification in a continuous rotation. Stopping the rotation during installation will cause the nylon lock to set incorrectly. This will cause incorrect torque readings while tightening the retainer, and lead to bearing failure. Install a new front axle wheel hub retainer every time after loosening the

7 Page 7 of 8 retainer or not installing the retainer to specification in a continuous rotation. CAUTION: Do not use power tool to tighten front axle wheel hub retainer. Use torque wrench. With steel rod inserted in brake disc (1032), install and tighten the new front axle wheel hub retainer to Nm ( lb-ft) in a continuous rotation. 8. For SHO only, install air suspension height sensor on height sensor ball studs. Install wiring harness and routing clip on front shock absorber. 9. Install front brake anti-lock sensor. Tighten retaining bolt to Nm ( lb-in). 10. Install front brake anti-lock sensor harness in the retaining clip. 11. Install tire and wheel assembly. Tighten lug nuts to Nm ( lb-ft). Install wheelcover or hub cover. 12. Lower vehicle. 13. Check and if necessary, fill transaxle to correct level with specified fluid. Refer to Section 07-01A (AX4S) or to Section 07-01B (AX4N).

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Halfshaft. Special Tool(s) Differential Plug (T89P-4850-B) Differential Seal Protector Halfshaft Removal Tool

Halfshaft. Special Tool(s) Differential Plug (T89P-4850-B) Differential Seal Protector Halfshaft Removal Tool Halfshaft Special Tool(s) Differential Plug 205-294 (T89P-4850-B) Differential Seal Protector 205-461 Halfshaft Removal Tool 205-475 Hub Remover/Replacer 204-069 (T81P-1104-C) Metric Hub Remover Adapter