Removing and installing drive shafts (Mondeo 1 and 2)

Removal

1. Remove the wheel cap. Apply the parking brake and engage first gear or set the selector to position "P". Loosen the hub nut by about half a turn. It is tightened with great force (see Fig. 2.1).



2. Loosen the front wheel mounting nuts. Apply the parking brake, lift the front end and place it on supports. Remove the wheel.

4. Remove the front brake disc (Chapter 9).

5. Completely loosen and remove the hub/drive shaft mounting nut. Note that this nut can be reinstalled no more than five times. It is a good idea to mark it with a small line each time you remove it. Purchase a new nut if necessary.

6. Hold the suspension strut piston with a hex key, loosen the nut of its upper support, and then unscrew it five turns. It is not necessary to remove the nut, but keep in mind that a new one will be required for installation. Disconnect the ABS wiring from the strut (if available).

7. Loosen the nut securing the anti-roll bar connecting link to the front suspension strut. Move the link to the side.



8. Remove the cotter pin from the ball joint nut located at the end of the tie rod. Remove the nut and disconnect the rod from the control arm on the steering knuckle using a ball joint puller. Be careful not to damage the ball joint seal.

9. Considering which side the front lower control arm ball joint clamp bolt is installed on, remove the bolt from the steering knuckle. Press the ball joint away from the steering knuckle. If this is difficult, gently pry the clamp apart with a flat-head power screwdriver or something similar. Be careful not to damage the ball joint seal.

10. Using a universal puller installed on the hub flange, press the drive shaft out of the hub and steering knuckle (see Fig. 2.10, a, b). After releasing the drive shaft, support it on a stand so that the inner joint does not rotate more than 18° (to prevent damage).

Left drive shaft

11. Insert a pry bar between the inner joint of the shaft and the transmission housing, placing a thin wooden shim between the pry bar and the housing. Press the inner joint away from the differential (see Fig. 2.11). If this is difficult, tap the pry bar with your palm.



12. Be careful not to damage adjacent components and be prepared to clean up any oil leaks.

13. Note that (non-automatic transmission models only) when the right-hand drive shaft is removed, the left-hand drive shaft can be released using a fork-end drift inserted from the right side. Be careful not to damage the differential gears.

14. Remove the shaft from under the vehicle.

15. Remove the elastic ring from the groove on the inner end of the shaft and purchase a new one.

Right drive shaft

16. The right drive shaft can be removed from the transmission together with the intermediate shaft, or it can be disconnected from the intermediate shaft. If you are disconnecting it from the intermediate shaft, then use a soft-faced hammer to sharply hit the housing of the inner constant velocity joint, knocking it off the intermediate shaft. The inner elastic ring can be removed, and the drive shaft can be pulled out of the splines.



17. Remove the elastic ring from the groove on the outer end of the intermediate shaft and purchase a new one.

18. If you are removing the right drive shaft assembly as a whole, proceed as follows. Unscrew the bolts securing the shaft support bearing bracket from the cylinder block, from its rear side, and remove the heat-insulating casing (see Fig. 2.18).



19. Remove the shaft assembly from the transmission and bearing bracket and remove it from under the vehicle (see Fig. 2.19). Be prepared to clean up any oil leaks.

Both shafts

20. Check the condition of the transmission seals and replace them if necessary (chapter 7A). Inspect the support bearing and replace if necessary (paragraph 13).

Installation

Right drive shaft

21. If the intermediate shaft has not been removed, proceed to step 24. If it has been removed, follow these instructions.

22. Carefully install the drive shaft assembly into the support bearing and into the transmission so as not to damage the seal. Rotate the shaft until it fits onto the differential splines.

23. Tighten the support bearing mounting bolts to the cylinder block bracket to the specified torque. Proceed to step 29.

24. Install a new elastic ring into the groove on the outer end of the intermediate shaft. Then apply 6-8 g of grease (Ford SQM1C-9004-A) to the splined part of the intermediate shaft around its circumference. This prevents friction corrosion.

25. Install the right-hand drive shaft onto the splines of the intermediate shaft and press down on the drive shaft until the inner elastic ring snaps into the groove of the shaft. (This will be audible.).

Left drive shaft

26. Install a new elastic ring into the groove on the inner end of the drive shaft.

27. Be careful not to damage the differential seal when inserting the shaft.

28. Insert the drive shaft into the transmission until the elastic ring snaps into place.

Both shafts

29. Pull the steering knuckle outward and insert the outer end of the drive shaft into the hub. Rotate the shaft until it is seated in the hub splines and pressed all the way in. Ford recommends a special tool for this operation, but it is unlikely that the splines will be tight. If they are, you will need to use one or make one.



30. Screw the nut onto the hub by hand.

31. Install the lower arm ball joint end of the front suspension into the steering knuckle from below. Insert the clamp bolt into its original position. Screw on the nut and tighten it to the required torque.

32. Install the ball joint of the tie rod end onto the steering knuckle and screw on the nut. Tighten it to the required torque.

33. The cotter pin holes on the ball joint nut must be aligned. If necessary, the nut can be tightened slightly to align the holes, but the tightening force must be within the tolerance for the required torque. Insert a new cotter pin and bend it.

34. Install the anti-roll bar connecting link to the front suspension strut and tighten the nut to the specified torque.

35. Remove the upper strut support nut and replace it with a new nut, tightening it to the specified torque (Chapter 10). Install the ABS wiring to the strut bracket (if equipped).

36. Install the front brake disc (Chapter 9).

37. Check the transmission oil level and top it up if necessary (chapter 1).

38. Install the wheel and lower the vehicle to the ground. Tighten the wheel nuts to the specified torque.

39. Fully tighten the hub nut to the required torque (see Fig. 2.39). Then install the wheel cap.