Lincoln Corsair: Front Drive Halfshafts / Removal and Installation - Intermediate Shaft

Materials

Removal

1. Remove the front halfshaft RH .
   Refer to: Front Halfshaft RH - AWD (205-04 Front Drive Halfshafts, Removal and Installation).
   

1. Remove and discard the circlip and O-ring seal from the intermediate shaft.
   

1. Remove and discard the intermediate shaft mounting bolts.
   

1. Install two 6mm x 1.0 x 20mm bolts into the flange threads.
   

1. Turn bolts evenly one turn at a time and remove the intermediate shaft.
   

1. Remove and discard the intermediate shaft bearing O-ring seal.
   

Installation

1. NOTE: Component(s) must be lubricated with clean automatic transmission fluid.

   
   Lubricate the new intermediate shaft bearing O-ring seal before installation with the specified material.
   
   • Material: Motorcraft® MERCON® ULV Automatic Transmission Fluid / XT-12-QULV (WSS-M2C949-A, ) (MERCON® ULV)

1. Install the new intermediate shaft bearing O-ring seal.
   

1. 1. Install the intermediate shaft in the PTU until the shaft flange is flush with the PTU housing.
      

   2. NOTE: Don't tap on the flange ears.

      
      

   3. NOTE: If necessary, tap on the bearing housing around the seal flange.

      
      

1. NOTE: Make sure that new bolts are installed.

   Install new bolts.
   Torque: 18 lb.ft (25 Nm)

1. Install the new circlip and O-ring seal on the intermediate shaft.
   

1. Install the front halfshaft RH .
   Refer to: Front Halfshaft RH - AWD (205-04 Front Drive Halfshafts, Removal and Installation).
   

1. Check the transmission fluid level.
   Refer to: Transmission Fluid Level Check (307-01B Automatic Transmission - Automatic Transmission – HF45, General Procedures).
   Refer to: Transmission Fluid Level Check (307-01B Automatic Transmission - Automatic Transmission – HF45, General Procedures).
   Refer to: Transmission Fluid Level Check (307-01B Automatic Transmission - Automatic Transmission – HF45, General Procedures).