Ford Fusion: Rear Drive Axle/Differential / Axle Assembly. Removal and Installation

Special Tool(s) / General Equipment

Materials

Removal

1. Remove the rear halfshafts.
   Refer to: Rear Halfshaft (205-05 Rear Drive Halfshafts, Removal and Installation).
   

1. Remove and discard the driveshaft to rear differential flange bolts and washer assemblies.
   Torque: 26 lb.ft (35 Nm)

1. NOTE: Do not remove driveshaft from the pinion flange by pulling on the driveshaft tube. Damage to the CV joint can result.

   
   Disconnect the driveshaft.
   
   1. Index-mark the driveshaft CV joint coupling and RDU (Rear Drive Unit) flange.
      
   2. Separate the driveshaft CV joint coupling from the RDU flange.
      
   3. Position and support the driveshaft aside.
      

1. Disconnect the ATC connector.
   

1. Disconnect the RDU vent tube.
   

1. Position and secure a transmission jack under the RDU.
   Use the General Equipment: Transmission Jack

1. Remove the rear RDU mounting bolts.
   Torque: 66 lb.ft (90 Nm)

1. Remove the front RDU mounting bolts and using the transmission jack, remove the RDU.
   Use the General Equipment: Transmission Jack
   Torque: 66 lb.ft (90 Nm)

1. If installing a new RDU.
   Remove the RDU mounting bracket bolts and mounting brackets.
   Torque: 66 lb.ft (90 Nm)

1. If installing a new RDU.
   Remove the RDU mounting bracket bolts and mounting brackets.
   Torque: 66 lb.ft (90 Nm)

Installation

1. NOTICE: If replacing the axle assembly, the 4X4 control module will need to be reconfigured with the new Active Torque Coupling (ATC) bar code information. If the new bar code information does not match the existing 4X4 control module information, driveline damage or driveability concerns can occur.

   If installing a new RDU, re-configure the Active Torque Coupling (ATC).
   Refer to: Four-Wheel Drive Systems (308-07A Four-Wheel Drive Systems, Diagnosis and Testing).
   

1. To install, reverse the removal procedure.
   

1. If empty, fill the rear axle with 0.55L (1.15 pt) of rear axle lubricant. If fluid level is low, fill to 3-5 mm (0.118-0.196 in) below the bottom of the filler hole and install the filler plug.
   Material: Motorcraft® SAE 80W-90 Premium Rear Axle Lubricant / XY-80W90-QL (WSP-M2C197-A)
   Torque: 21 lb.ft (29 Nm)