Ford Fusion: Front Drive Halfshafts / Front Drive Halfshafts. Diagnosis and Testing

Ford Fusion 2013–2020 Service Manual / Chassis / Driveline / Front Drive Halfshafts / Front Drive Halfshafts. Diagnosis and Testing

Preliminary Inspection

Visually inspect the CV joints, housing, boots, and clamps for obvious signs of mechanical damage.

If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step

If the cause is not visually evident, verify the symptom and REFER to Symptom Chart: NVH.

Symptom Chart(s)

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.
REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).

Symptom Chart: NVH

Symptom Chart

Condition	Possible Sources	Actions
Axle howling or whine – front or rear axle	Damaged or worn wheel hub bearings	CHECK for abnormal wheel hub bearing play or roughness. REFER to: Front Wheel Bearing and Wheel Hub (204-01 Front Suspension, Removal and Installation).
Driveline clunk - loud clunk when shifting from REVERSE to DRIVE	Damaged or worn Constant Velocity (CV) joints	INSPECT the Constant Velocity (CV) joints for wear or damage. INSTALL a new halfshaft or driveshaft as necessary. REFER to: Front Halfshaft RH (205-04 Front Drive Halfshafts, Removal and Installation). REFER to: Front Halfshaft LH (205-04 Front Drive Halfshafts, Removal and Installation).
	Loose hub nut	CHECK the torque on the hub nut. REPLACE the hub nut if the torque is not at specification. For front hub nuts. REFER to: Front Halfshaft RH (205-04 Front Drive Halfshafts, Removal and Installation). REFER to: Front Halfshaft LH (205-04 Front Drive Halfshafts, Removal and Installation).
Driveline clunk (Front Wheel Drive (FWD) vehicles) — occurs during acceleration or from cruise to coast/deceleration	Damaged or worn Constant Velocity (CV) joints	INSPECT the inner Constant Velocity (CV) joint and boot. INSTALL a new halfshaft as necessary. REFER to: Front Halfshaft RH (205-04 Front Drive Halfshafts, Removal and Installation). REFER to: Front Halfshaft LH (205-04 Front Drive Halfshafts, Removal and Installation).
	Loose hub nut	CHECK the torque on the hub nut. REPLACE the hub nut if the torque is not at specification. REFER to: Front Halfshaft RH (205-04 Front Drive Halfshafts, Removal and Installation). REFER to: Front Halfshaft LH (205-04 Front Drive Halfshafts, Removal and Installation).
Driveline clunk — occurs as the vehicle starts to move forward following a stop	Loose hub nut	CHECK the torque on the hub nut. REPLACE the hub nut if the torque is not at specification. REFER to: Front Halfshaft RH (205-04 Front Drive Halfshafts, Removal and Installation). REFER to: Front Halfshaft LH (205-04 Front Drive Halfshafts, Removal and Installation).
Clicking, popping or grinding - occurs while the vehicle is turning	Inadequate or contaminated lubrication in the Constant Velocity (CV) joints	CHECK the Constant Velocity (CV) boots and joints for wear or damage. INSTALL new components as necessary. REFER to: Front Halfshaft RH (205-04 Front Drive Halfshafts, Removal and Installation). REFER to: Front Halfshaft LH (205-04 Front Drive Halfshafts, Removal and Installation). CHECK the halfshafts and the area around the halfshafts. REPAIR as necessary. CHECK the halfshafts and the area around the halfshafts. Install an outer halfshaft thrust washer between the outer CV joint housing and the hub interface as necessary.
	Another component contacting the halfshaft	CHECK the halfshafts and the area around the halfshafts. REPAIR as necessary.
Grunting — normally associated with a shudder experienced during acceleration from a complete stop	Halfshaft to hub interface.	INSTALL or REPLACE thrust washer between the halfshaft and hub. The nylon surface should face outward toward the hub/splines.
Ting, pop, or click noise from the front wheel area when accelerating from a stop or when shifting between drive/reverse and/or reverse/drive.	Halfshaft Constant Velocity (CV) joint binding	CHECK the outer Constant Velocity (CV) joint for correct seating into the hub. REPAIR as necessary. REFER to: Front Halfshaft RH (205-04 Front Drive Halfshafts, Removal and Installation). REFER to: Front Halfshaft LH (205-04 Front Drive Halfshafts, Removal and Installation).
Driveline vibration - occurs at cruising speeds	Incorrectly seated Constant Velocity (CV) joint in the wheel hub	CHECK the outer CV joint for correct seating into the hub. REPAIR as necessary. REFER to: Front Halfshaft RH (205-04 Front Drive Halfshafts, Removal and Installation). REFER to: Front Halfshaft LH (205-04 Front Drive Halfshafts, Removal and Installation). REFER to: Front Wheel Bearing and Wheel Hub (204-01 Front Suspension, Removal and Installation).

Specifications

Front Halfshaft LH. Removal and Installation

Special Tool(s) / General Equipment 204-161 (T97P-1175-A) Installer, HalfshaftTKIT-1997-LM2TKIT-1997-F/FM2TKIT-1997-FLM2 205-D070 (D93P-1175-B) Remover, Front Wheel Hub Removal Remove the wheel and tire...

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