Thursday, March 8, 2012

Ford Model Rear and Front Halfshafts Removal Procedure?

Front and Rear Halfshaft Removal procedure is for
Lincoln Aviator, Ford Explorer, Exp Sport, Exp Sport-Trac, Mercury Mountaineer 2000-2005.


Removal & Installation
FRONT
REAR

The instructions with proper details and diagrams are mentioned below.


  1. Before servicing the vehicle, refer to the Precautions section.
  2. Remove or disconnect the following:

    Negative battery cable
    Front wheel
    Manual locking hub assembly from the rotor by pulling straight outward
    Plastic stub shaft retainer
    Front disc brake caliper from the anchor and move it aside. Support the front suspension lower arm.
    Upper ball joint from the steering knuckle
    Outboard front driveshaft from the hub
    Halfshaft from the axle housing
    Driveshaft and joint from the axle housing
To install:
  1. Install or connect the following:

    Halfshaft and joint to the axle housing
    Outboard front driveshaft to the hub
    Upper ball joint to the steering knuckle
    Brake caliper to the anchor and remove the front suspension support
    New stub shaft retainer
    Locking hub to the brake rotor
    Front wheel
    Negative battery cable

Front





Click image to see an enlarged view
Fig. Front axle halfshaft
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2. Remove or disconnect the following:
  3. Loosen the front axle wheel hub retainer.
    WARNING
    Do not allow the knuckle to hang freely. It is possible to overextend and internally separate each inner CV-joint from its housing.


    WARNING
    Do not use a hammer to separate the outboard CV-joint from the hub. Damage to the threads and internal CV-joint components may result.



    Wheel and tire assembly
    Hub retainer and the washer. Discard the front axle wheel hub retainer.
    The two bolts and position the disc brake caliper aside
    Tie-rod end from the knuckle. Discard the nut.
    Stabilizer bar link. Discard the nut.



    Upper ball joint from the knuckle
  4. Press the outboard CV-joint until it is loose in the hub.
  5. Remove the outboard CV-joint from the hub.
    WARNING
    Do not damage the axle shaft oil seal or the machined sealing surface on the inboard CV-joint housing.


    NOTE
    A circlip retains the inboard CV-joint housing to the differential side gear in the axle.
  6. On the left side, pry the left inboard CV-joint housing from the differential side gear.
  7. On the right side, disengage the right inboard CV-joint housing from the axle tube.
  8. Pull the halfshaft and the axle shaft away from the axle tube, and separate the inboard CV-joint housing from the axle shaft.
  9. Remove the halfshaft assembly from the vehicle.
    WARNING
    Do not damage the axle shaft oil seal, the machined sealing surface on the inboard CV-joint housing, or the axle shaft splines.
To install:
  1. Installation is the reverse of the removal procedure.
  2. Always install the halfshaft with a new retainer circlip and a new front axle wheel hub retainer.
  3. On the right side, check the retainer circlip engagement after reseating the axle shaft and after installing the halfshaft in the axle. On the left side, check the retainer circlip engagement after installing the halfshaft in the axle. When seated, the retainer circlip will lock the axle shaft and the inboard CV-joint housing to the axle.
    WARNING
    Never use power tools to tighten the front axle wheel hub retainer. Torque the retainer to 184 ft. lbs. (250 Nm).


    NOTE
    It may be necessary to support the front suspension lower arm to be able to connect the upper ball joint to the knuckle.
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Remove or disconnect the following:
  3. Loosen the front axle wheel hub retainer.
    WARNING
    Do not allow the knuckle to hang freely. It is possible to overextend and internally separate each inner CV joint from its housing.


    WARNING
    Do not use a hammer to separate the outboard CV joint from the hub. Damage to the threads and internal CV joint components may result.



    Wheel and tire assembly
    Hub retainer and the washer. Discard the front axle wheel hub retainer.
    The two bolts and position the disc brake caliper aside
    Tie-rod end from the knuckle. Discard the nut.
    Stabilizer bar link. Discard the nut.



    Upper ball joint from the knuckle
  4. Press the outboard CV joint until it is loose in the hub.
  5. Remove the outboard CV joint from the hub.
    WARNING
    Do not damage the axle shaft oil seal or the machined sealing surface on the inboard CV joint housing.


    NOTE
    A circlip retains the inboard CV joint housing to the differential side gear in the axle.
  6. On the left side, pry the LH inboard CV joint housing from the differential side gear.
  7. On the right side, disengage the RH inboard CV joint housing from the axle tube.
  8. Pull the halfshaft and the axle shaft away from the axle tube, and separate the inboard CV joint housing from the axle shaft.
  9. Remove the halfshaft assembly from the vehicle.
    WARNING
    Do not damage the axle shaft oil seal, the machined sealing surface on the inboard CV joint housing, or the axle shaft splines.
  10. To install, reverse the removal procedure.
  11. Always install the halfshaft with a new retainer circlip and a new front axle wheel hub retainer.
  12. On the right side, check the retainer circlip engagement after reseating the axle shaft and after installing the halfshaft in the axle. On the LH side, check the retainer circlip engagement after installing the halfshaft in the axle. When seated, the retainer circlip will lock the axle shaft and the inboard CV joint housing to the axle.
    WARNING
    Never use power tools to tighten the front axle wheel hub retainer. Torque the retainer to 184 ft. lbs. (250 Nm).


    NOTE
    It may be necessary to support the front suspension lower arm to be able to connect the upper ball joint to the knuckle.

Rear





Click image to see an enlarged view
Fig. Rear axle halfshaft
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2. Remove or disconnect the following:
    WARNING
    Do not loosen the rear axle wheel hub retainer until after the wheel and tire assembly are removed from the vehicle. Wheel bearing damage will occur if the wheel bearing is unloaded with the weight of the vehicle applied.


    NOTE
    Have an assistant press the brake pedal to keep the axle from rotating.


    WARNING
    Using a rubber hose approximately 37.5 mm (1.5 in) long, cover the stabilizer link bolt threads and nut to prevent boot damage when removing the halfshaft assembly from the vehicle.


    WARNING
    The bolt that retains the upper ball joint to the knuckle is longer and it has fewer threads than the bolt that retains the toe link to the knuckle. Switching these bolts during installation will prevent the pinch arms on the knuckle from correctly retaining the toe link to the knuckle. This may cause the toe link to separate from the knuckle during vehicle operation. Failure to follow these instructions may result in personal injury.


    WARNING
    Using a wood stick, approximately 450 mm (18 in) long and 25 mm (1 in) wide, support the rear suspension upper arm to prevent boot damage when removing the halfshaft assembly from the vehicle


    NOTE
    Do not use a hammer to separate the outboard CV-joint from the hub. Damage to the threads and internal CV-joint components may result. Once the outboard CV-joint separates from the hub the knuckle will continue to pivot until the brake backing plate presses against the suspension lower arm. To prevent damage to the brake backing plate, immediately after separating the outboard CV-joint from the hub, rest the knuckle on a cushioned support that is tall enough to keep the backing plate from pressing against the suspension lower arm.



    Wheel and tire assembly



    Hub retainer and the washer
    Caliper. Position the disc brake caliper out of the way.
    Brake disc
    Bolt retaining the parking brake cable bracket to the frame



    Pinch bolts and disconnect the toe link and upper ball joint from the knuckle



    Click image to see an enlarged view
    Fig. Using a wood stick, approximately 450 mm (18 in) long and 25 mm (1 in) wide, support the rear suspension upper arm to prevent boot damage when removing the halfshaft assembly from the vehicle
  3. Press the outboard CV-joint until it is loose in the hub.
  4. Separate the outboard CV-joint from the hub.
  5. Rest the knuckle on a cushioned support.
    WARNING
    Do not damage the axle shaft oil seal or the machined sealing surface on the inboard CV-joint housing.


    NOTE
    A circlip retains the inboard CV-joint housing to the differential side gear in the axle.
  6. Using the special tool, disengage the inboard CV-joint housing from the differential side gear.
    WARNING
    To prevent damage to the axle shaft oil seal, install the special tool 205-461 (seal protector) before removing the inboard CV-joint housing from the axle.
  7. Remove the halfshaft assembly from the vehicle.
To install:
  1. Installation is the reverse of the removal procedure.
  2. To prevent damage to the axle shaft oil seal, install the seal protector before positioning the inboard CV-joint housing in the axle.
  3. Always install the halfshaft with a new retainer circlip and a new rear axle wheel hub retainer.
    NOTE
    Never use power tools to tighten the rear axle wheel hub retainer. Torque the retainer to 203 ft. lbs. (275 Nm).
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Remove or disconnect the following:
    WARNING
    Do not loosen the rear axle wheel hub retainer until after the wheel and tire assembly are removed from the vehicle. Wheel bearing damage will occur if the wheel bearing is unloaded with the weight of the vehicle applied.


    NOTE
    Have an assistant press the brake pedal to keep the axle from rotating.


    WARNING
    Using a rubber hose approximately 37.5 mm (1.5 in) long, cover the stabilizer link bolt threads and nut to prevent boot damage when removing the halfshaft assembly from the vehicle.


    WARNING
    The bolt that retains the upper ball joint to the knuckle is longer and it has fewer threads than the bolt that retains the toe link to the knuckle. Switching these bolts during installation will prevent the pinch arms on the knuckle from correctly retaining the toe link to the knuckle. This may cause the toe link to separate from the knuckle during vehicle operation. Failure to follow these instructions may result in personal injury.


    WARNING
    Using a wood stick, approximately 450 mm (18 in) long and 25 mm (1 in) wide, support the rear suspension upper arm to prevent boot damage when removing the halfshaft assembly from the vehicle.


    NOTE
    Do not use a hammer to separate the outboard CV joint from the hub. Damage to the threads and internal CV joint components may result. Once the outboard CV joint separates from the hub the knuckle will continue to pivot until the brake backing plate presses against the suspension lower arm. To prevent damage to the brake backing plate, immediately after separating the outboard CV joint from the hub, rest the knuckle on a cushioned support that is tall enough to keep the backing plate from pressing against the suspension lower arm.



    Wheel and tire assembly



    Hub retainer and the washer
    Caliper. Position the disc brake caliper out of the way.
    Brake disc
    Bolt retaining the parking brake cable bracket to the frame



    Pinch bolts and disconnect the toe link and upper ball joint from the knuckle
  3. Press the outboard CV joint until it is loose in the hub.
  4. Separate the outboard CV joint from the hub.
  5. Rest the knuckle on a cushioned support.
    WARNING
    Do not damage the axle shaft oil seal or the machined sealing surface on the inboard CV joint housing.


    NOTE
    A circlip retains the inboard CV joint housing to the differential side gear in the axle.
  6. Using the special tool, disengage the inboard CV joint housing from the differential side gear.
    WARNING
    To prevent damage to the axle shaft oil seal, install the special tool 205-461 (seal protector) before removing the inboard CV joint housing from the axle.
  7. Remove the halfshaft assembly from the vehicle.
  8. To install, reverse the removal procedure.
  9. To prevent damage to the axle shaft oil seal, install the seal protector before positioning the inboard CV joint housing in the axle.
  10. Always install the halfshaft with a new retainer circlip and a new rear axle wheel hub retainer.
    NOTE
    Never use power tools to tighten the rear axle wheel hub retainer. Torque the retainer to 251 ft. lbs. (340Nm).



This will help.
Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html


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