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HOMESERVICE MANUALSFORD2007FUSION SEL, 2.3 Z, STANDARDREPAIR AND DIAGNOSIS (SINGLE PAGE)DRIVELINES & AXLESAXLE SHAFTSFRONT DRIVE HALFSHAFTSREMOVAL AND INSTALLATIONINTERMEDIATE SHAFT - ALL WHEEL DRIVE (AWD)INSTALLATION
2007 Ford Fusion SEL, 2.3 Z, Standard

Intermediate Shaft - All Wheel Drive (AWD): Installation

2007 Ford Fusion SEL, 2.3 Z, StandardSECTION Installation
    CAUTION: Make sure to install the correct circlip for each application. Failure to use the correct diameter circlip may result in shaft removal concerns or shaft separation during vehicle operation.
  1. Install a new circlip on the outboard end of the intermediate shaft.
    2. Fig 1: Identifying Halfshaft Retainer Circlip
    GF0022382Courtesy of FORD MOTOR CO.
  2. Install a new intermediate shaft seal. For additional information, refer to TRANSFER CASE - POWER TRANSFER UNIT (PTU) .
  3. Position the intermediate shaft in the transaxle and engage the intermediate shaft splines with the transaxle side gears. Make sure the circlip is locked in the gear.
  4. Install the 2 intermediate shaft support bracket bolts.
    • Tighten to 40 Nm (30 lb-ft).
  5. Install the right halfshaft. For additional information, refer to Halfshaft - RH .
RENDER: 1.0x

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Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.