Ford Fusion: Driveshaft / Rear Driveshaft. Removal and Installation

Special Tool(s) / General Equipment

Removal

NOTE: The max articulation of any CV is 10 degrees. The max articulation of any U-joint is 12 degrees. If the CV or any U-joint of the driveshaft is articulated further then the max allowable degrees damage may occur.

NOTE: Removal steps in this procedure may contain installation details.

1. Remove the muffler and tailpipe.
   Refer to: Muffler and Tailpipe (309-00A Exhaust System - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
   Refer to: Muffler and Tailpipe (309-00C Exhaust System - 2.5L Duratec (125kW/170PS), Removal and Installation).
   Refer to: Muffler and Tailpipe (309-00D Exhaust System - 2.7L EcoBoost (238kW/324PS), Removal and Installation).
   Refer to: Muffler and Tailpipe (309-00B Exhaust System - 2.0L EcoBoost (184kW/250PS) – MI4, Removal and Installation).
   

1. If equipped.
   Remove the retainers and the underbody shield.
   

1. If equipped.
   Remove the retainers and the front air deflectors.
   

1. NOTE: The installation step requires the aid of another technician.

   Remove and discard the driveshaft to PTU bolts and the retaining straps.
   Torque: 26 lb.ft (35 Nm)

1. 
   Separate the driveshaft from the PTU flange.
   

   1. NOTE: Make sure that the component aligns with the installation mark.

      Index-mark the driveshaft and PTU flange.
      

   2. NOTICE: Do not remove driveshaft from the PTU flange by pulling on the driveshaft tube. Damage to the CV-joint can result.

      NOTE: This is a tight fit, do not remove the CV flange from the PTU flange at this time.

      Using general equipments, separate the driveshaft from the PTU flange.
      Use the General Equipment: Punch
      Use the General Equipment: Copper Hammer
   3. Remove the driveshaft from the PTU flange.
      

1. 
   Separate the driveshaft from the drive pinion flange.
   
   1. Remove and discard the driveshaft to RDU bolts and the retaining straps.
      Torque: 26 lb.ft (35 Nm)

   2. NOTE: Make sure that the component aligns with the installation mark.

      Index-mark the driveshaft and RDU flange.
      

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

      NOTE: The driveshaft to drive pinion flange is a tight fit and will not come apart until the rear differential is removed.

      Using a general equipment, separate the driveshaft from the drive pinion flange.
      Use the General Equipment: Flat-Bladed Screwdriver

1. NOTICE: Do not over articulate the driveshaft or damage may occur.

   NOTICE: The driveshaft is long and heavy with multiple U-joints. The help of a assistant will be needed. Do not over articulate the driveshaft or damage may occur.

   NOTE: The max articulation of any CV is 10 degrees. The max articulation of any U-joint is 12 degrees. If the CV or any U-joint of the driveshaft is articulated further then the max allowable degrees damage may occur.

   1. Remove and discard the rear center bearing bracket bolts.
      Torque: 22 lb.ft (30 Nm)
   2. Remove and discard the front center bearing bracket bolts.
      Torque: 41 lb.ft (55 Nm)

   3. NOTE: When installing the driveshaft, it will be necessary to place the CV joint flanges of the driveshaft into the PTU and RDU flanges before installing the center bearing bolts.

      With an assistant remove the driveshaft.
      

Installation

1. NOTE: If a driveshaft is installed and driveshaft vibration is encountered after installation, index the driveshaft.

   To install, reverse the removal procedure.