Tuesday, June 14, 2011

how to remove drive axle from the differential on ford focus?

Within the differential are several bearings, which periodically require service. However, the differential cannot be serviced until both drive axles have first been removed.

  • Loosen each lug nut on both rear wheels with a tire iron or with an impact wrench.

  • Elevate the rear of the vehicle with a shop jack underneath the differential.

  • Slide a safety stand underneath both axle housings, then lower the vehicle onto the stands.

  • Disengage the parking brake and remove the shop jack.

  • Remove the loosened lug nuts from both rear tires, then pull the tires off of the axles.

  • Pull the brake drum off of the drive axles to expose the axle's mounting plate, if the vehicle is equipped with drum brakes.

  • Remove the axle shaft's retaining bolts. The metal disk at the tip of each axle shaft consists of a number of studs, over which the wheel mounts and a single circle. This circle's sole purpose is the enable a socket wrench to access and remove the axle's retaining bolts. Insert a deep-socket connected to a socket wrench through the access circle to remove the bolts. Rotate the axle shaft to move the circle until each bolt has been removed. The precise number of bolts varies depending on the model of the vehicle, but there are typically four or five mounting bolts.

  • Grasp the back of the metal disk at the tip of the axle shaft; then pull the axle straight out of the axle housing.



  • A drive axle connects the transaxle assembly of the Ford Focus to the drive wheels. The axle itself is nothing more than a shaft with two flexible joints on either end. One end is connected to the transaxle and the other is connected to the wheel hub assembly. Axles don't usually break, but the joints on the axles will fail occasionally. When this happens, rather than replace the joints, it is usually cheaper and more efficient to simply replace the entire drive axle.
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  • This tools are required:---

  • Tire wrench
  • Jack with 2 jack stands
  • Pliers
  • Spindle nut socket
  • Socket wrench with socket set
  • Impact wrench with air compressor
  • Tie rod end puller
  • Flathead screwdriver
  • Zip ties
  • Hard grease
  • New cotter pin

  • Break the lug nuts loose on the wheel with the drive axle you want to replace. Turn the lug nuts 45 degrees using a tire wrench.

  • Put the emergency brake on and jack up the car using the front jack point. Put a jack stand under each of the front pinch welds and lower the Focus onto the stands.

  • Remove the lug nuts and wheel.

  • Loosen and remove the spindle nut using the spindle nut socket and impact wrench.

  • Remove the upper and lower brake caliper mounting bolts. Secure the caliper to the coil springs with zip ties.

  • Remove the brake rotor from the hub. It will pull straight off the hub assembly.

  • Pull the cotter pin from the drive shaft nut with pliers.

  • Remove the drive shaft nut using the impact wrench.

  • Remove the tie rod bolt.

  • Remove the tie rod bolt, and negotiate the steering knuckle and wheel hub assembly out of the way so that you can pull the axle out of the transaxle.

  • Pull the drive axle out of the hub assembly.

  • Install the new drive axle. Installation is the reverse of removal.

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    How to Remove the Inside Axle Nut on a Ford Focus
    The axle nut, or spindle nut as it is formally known, is the same size from 2000 to present. Removal of the spindle nut is usually done to assist in access to wheel bearings and suspension or steering parts.

    Tools required:--

  • Tire iron
  • Jack stand
  • 2-ton jack or greater capacity
  • 1/2-inch drive breaker bar
  • PB Blaster penetrating spray
  • 32-mm spindle socket
  • Flat head screwdriver
  • 3/8-inch drive ratchet and socket set
  • Wheel chocks

  • Lift the wheel from which you want to remove the axle nut off the ground. Set a jack stand underneath the control arm if it is a front wheel, or the rear axle beam if is on the rear wheel. Remove the wheel from the car. Place a wheel chock in front of the wheel you are not working on, on the same side of the car that you are working on. For example, if you're working on the driver's front tire, put the wheel chock in front of the driver's rear tire. Use extra wheel chocks on the opposite side of vehicle, if available.

  • Spray PB Blaster penetrating spray onto the center of the hub, or where the hole is in the middle of the brake rotor. If you have drum brakes on the rear, you must dismantle all of the drum brakes and hardware to remove the spindle nut. Use a flat head screwdriver to pry the rear brake hardware springs off and dismantle the rest by hand. Remove the backing plate from the rear spindle using a 3/8-inch drive ratchet and socket, prior to attempting removal of the spindle nut.

  • Set a 32-mm spindle socket onto a 1/2-inch drive breaker bar.

  • Align the spindle nut socket up with the axle nut you wish to remove. Turn the axle nut counterclockwise to remove it from the axle. There may be over 150 foot-pounds of torque on your spindle nut if it is a factory set nut. Do not stand on the breaker bar to apply pressure. Turn your body so that your back faces the front of the car, and use your upper body for the leverage you need to remove the initial torque.


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    HOW to remove half-shafts:---


    CV-Joints



    Overhaul
    Inner
    1. Before servicing the vehicle, refer to the Precautions Section.
    2. Remove the axle halfshaft from the vehicle and place it in a vise.
    3. Remove or disconnect the following:

      Tripod joint boot clamps
      Tripod joint boot
      Tripod joint housing
      Snap ring
      Tripod joint


    To install:


    NOTE
    Use new snap rings and boot clamps for assembly.

    1. Install or connect the following:

      Tripod joint
      Snap ring
      Tripod joint housing. Fill the joint housing with grease.
      Tripod joint boot
      Tripod joint boot clamps

    2. Install the halfshaft.

    Outer
    1. Remove the Inner CV-Joint.
    2. Remove the outer boot clamps.
    3. Remove the outer boot.

    To install:

    1. Slide the outer boot outwards over the CV-joint.
    2. Press the boot into the annular groove on the drive joint.
    3. Slide a small screwdriver under the boot seat to allow the air to escape.
    4. Locate the boot in position and remove the screwdriver.
    5. Install the boot clamps.
    6. Install the inner CV-Joint.

    Removal & Installation



    Left

    NOTE
    The hub nut may be reused 4 times. Mark the nut at removal and only use hub nuts with 3 or fewer marks for assembly.

    1. Before servicing the vehicle, refer to the Precautions Section.
    2. Loosen the LH strut and spring assembly mounting nuts by 4 turns.
    3. Remove or disconnect the following:

      Front wheel
      Hub retainer nut. Mark the nut.
      Lower ball joint from the knuckle

    4. After separating the lower control arm from the wheel knuckle, immediately install the special tool over the ball stud before releasing the lower control arm and knuckle into rest positions. Leave the special tool in place during service and only remove prior to reassembly.

      Click image to see an enlarged view

      Fig. Install the special tool over the ball stud prior to releasing the lower control arm and knuckle

    5. Remove the hub nut, and then press the stub shaft out of the wheel hub.
      CAUTION
      Support the halfshaft. The inner joint must not be bent at more than 18 degrees.

    6. Separate the inner CV-joint from the transaxle as follows:


    7. Remove the LH drive halfshaft from the transaxle, using a slide hammer as shown.
    8. Close off the transaxle opening with an auxiliary plug.

      Click image to see an enlarged view

      Fig. Remove the LH drive halfshaft from the transaxle, using a slide hammer as shown


    To install:


    NOTE
    Replace the self-locking nuts and circlip for assembly.


    CAUTION
    Support the halfshaft. The inner halfshaft joint must not be bent by more than 18 degrees.


    CAUTION
    Do not damage the oil seal when inserting the front drive halfshaft.

    1. Install the LH drive halfshaft and snap ring into the transaxle. Make sure the snap ring is fully engaged, by pulling on the joint housing.

      Click image to see an enlarged view

      Fig. Install the LH drive halfshaft and snap ring into the transaxle; make sure the snap ring is fully engaged, by pulling on the joint housing

    2. Using the special tool, install the LH halfshaft stub into the wheel hub.

      Click image to see an enlarged view

      Fig. Using the special tool, install the LH halfshaft stub into the wheel hub

    3. Check the transmission fluid level.
    4. Attach the LH lower arm.
    5. Remove the special tool and attach the lower arm ball joint.
    6. Install the lower arm bolt and nut. Tighten to 48 Nm (35 lb-ft).
      CAUTION
      Do not tighten the front wheel hub nut with the vehicle on the ground. The nut must be tightened to specification before the vehicle is lowered onto the wheels. Wheel bearing damage will occur if the wheel bearing is loaded with the weight of the vehicle applied.

    7. Install a new wheel hub retaining nut. Tighten to 199 ft. lbs. (270 Nm).
    8. Install the LH wheel and tire assembly.
    9. Tighten the LH strut and spring assembly-to-mount nuts. Tighten to 22 ft. lbs. (30 Nm).

    Right
    1. Loosen the right hand strut and spring assembly by loosening the mounting bolts by five turns.
    2. Loosen the hub nut.
    3. Remove the right hand tire.
    4. Remove the lower ball joint nut and detach the lower control arm.
      CAUTION
      Do not use a prying device or separator fork between the lower ball joint and knuckle. Use a pry bar by inserting it into the lower control arm opening.

    5. Install Special Tool 307-102 over the ball stud before releasing the lower control arm and knuckle into rest positions.
    6. Unscrew the hub nut and detach the right hand halfshaft from the wheel hub using a suitable puller.
    7. Remove the retaining clip nuts.
    8. Pull out the right hand halfshaft and intermediate shaft as an assembly.
      CAUTION
      Support the halfshaft. The inner halfshaft joint must not be bent by more than 18 degrees.



      Click image to see an enlarged view

      Fig. Installing Special Tool 307-102 on the lower ball stud.



      Click image to see an enlarged view

      Fig. Using puller 204-069 to detach the halfshaft from the wheel hub.



      Click image to see an enlarged view

      Fig. Location of the intermediate shaft retaining nuts


    To install:

    1. Install the halfshaft/intermediate shaft assembly.
    2. Using new nuts, install the retaining clip and tighten to 18 ft. lbs. (25 Nm).
    3. Install or connect the following:

      Wheel hub retaining nut
      Lower control arm
      Lower ball joint

    4. Tighten the right hand strut and spring assembly mounting bolts.

    -----------------

    Transaxle Removal & Installation

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

      Negative battery cable
      Battery tray
      Air cleaner resonator
      LH strut and spring assembly top mount nuts by four turns
      Transmission Range (TR) sensor
      Transaxle solenoid connector

      Click image to see an enlarged view

      Fig. Showing the location of the TR sensor (1) and the solenoid connector (2)

      Turbine Shaft Speed (TSS) sensor

      Click image to see an enlarged view

      Fig. Disconnect the TSS sensor

      Electrical connector bracket nuts and move aside
      Upper center converter housing bolts

      Click image to see an enlarged view

      Fig. Remove the upper center convert housing bolts


    3. Using special tool 303-290, or a suitable harness and crane, support the engine from above.
    4. Remove or disconnect the following:
      NOTE
      Plug the transaxle openings to prevent contamination.



      Transmission fluid fill tube
      Shift cable bracket bolts

      Click image to see an enlarged view

      Fig. Remove the shift cable bracket bolts

      Starter motor and isolator
      Right hand engine support insulator

      Click image to see an enlarged view

      Fig. Remove the RH engine support insulator bolts and nut (1, 2)

      Left hand stabilizer bar at the strut
      Tie rod ends from the knuckles, using Special Tool 211-001
      Lower control arms from the knuckles
      Right hand halfshaft from the transmission and hang securely aside
      Left hand halfshaft from the transmission and hang securely aside



      Output Speed Sensor (OSS) connector
      Transmission cooler lines

      Click image to see an enlarged view

      Fig. Remove the transmission cooler lines from the fittings and quick-connect couplings

      Shift cable from manual control lever

    5. Remove the plastic cover and rotate the crankshaft to gain access to the converter nuts. Remove the four nuts.
      NOTE
      Before removal, mark one stud location to the flexplate for reinstallation reference.

    6. Remove the rear engine mount and lower the engine/transaxle assembly slightly.
    7. Remove the rear engine mount bracket.
    8. Secure the transaxle to a jack or suitable lifting device using a safety strap.
    9. Remove the converter housing bolts and separate the transaxle from the engine.
      NOTE
      Note the locations of the different bolt lengths.

    10. Install the holding tool, 307-346, to prevent damage to the torque converter.

      Click image to see an enlarged view

      Fig. Install the holding tool, 307-346, to prevent damage to the torque converter


    To install:

    1. Position the transaxle into position onto the engine assembly.
    2. Install the converter housing bolts and tighten to 35 ft. lbs. (47 Nm).
    3. Using new self-locking nuts, install the torque converter to the flexplate. Tighten the nuts to 27 ft. lbs. (37 Nm).
    4. Raise the engine/transaxle assembly into place and install the rear engine mount. Tighten the bracket bolts to 59 ft. lbs. (80 Nm). Tighten the outer engine mount bolts to 35 ft. lbs. (48 Nm). Tighten the center nut to 98 ft. lbs. (133 Nm).
    5. Install or connect the following:

      Transmission cooler lines
      OSS connecter
      Left hand halfshaft
      Right hand halfshaft
      Lower control arms to the knuckles
      Tie rod ends to the knuckles
      Stabilizer bar to the strut
      Right hand engine support isolator and tighten to 35 ft. lbs. (48 Nm)
      Starter motor
      Transmission fluid fill tube
      Shift cable bracket bolts
      Upper center converter housing bolts and tighten to 35 ft. lbs. (47 Nm)
      Electrical connector bracket
      TSS sensor
      TR sensor
      Transaxle solenoid connector
      LH strut upper mounting nuts; tighten to 22 ft. lbs. (30 Nm)
      Air cleaner resonator
      Battery tray
      Negative battery cable

    6. Fill the transmission to the correct level.
    7. Start the engine and check for leaks.
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