Ford Freestar, Monterey 2004-2006

Removal & Installation

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Automatic Transaxle




NOTE
Do not begin this removal procedure unless a new wheel hub retainer nut, a new retainer circlip and a new lower ball joint-to-front wheel knuckle retaining bolt and nut are available. Once removed, these parts must not be reused during assembly. Their torque holding ability, or retention capability, is diminished during removal.

  1. Remove or disconnect the following:

    Front wheels
     
    ABS sensor
     
    Brake caliper and wire aside
     
    Axle hub nut and washer. Discard the nut.
     
    Lower control arm ball joint pinch bolt and nut and discard them
     

  2.  
  3. Separate the outboard CV-joint from the wheel hub using a front hub remover/replacer. Make sure the hub remover adapter is fully threaded onto the hub stud.
  4.  
  5. Separate the halfshaft from the hub, and pull the halfshaft out of the transaxle.

    Click image to see an enlarged view

    Fig. Exploded view of front halfshaft mounting



    Click image to see an enlarged view

    Fig. Remove the halfshaft from the transaxle using a puller

  6.  

To install:


WARNING
Do not reuse the retainer circlip. A new circlip must be installed each time the inboard CV-joint stub shaft is installed into the transaxle differential.

  1. Install a new retainer circlip on the inboard CV-joint stub shaft by starting one end in the groove and working the retainer circlip over the inboard shaft housing end and into the groove. This will avoid over-expanding the circlip.
    NOTE
    A non-metallic mallet may be used to aid in seating the retainer circlip into the differential side gear groove. If a mallet is necessary, tap only on the outboard CV-joint shaft.

  2.  
  3. Carefully align the splines of the inboard CV-joint stub shaft housing with the splines in the differential. Exerting some force, push the inboard CV-joint stub shaft housing into the differential until the retainer circlip is felt to seat in the differential side gear. Use care to prevent damage to the inboard CV-joint stub shaft and transaxle seal.
  4.  
  5. Carefully align the splines of the outboard CV-joint with the splines in the wheel hub and push the shaft into the wheel hub as far as possible.
  6.  
  7. Temporarily fasten the front disc brake rotor to the wheel hub with washers and 2 lug nuts. Insert a steel rod into the front disc brake rotor and rotate clockwise to contact the front wheel knuckle to prevent the front disc brake rotor from turning when the nut is tightened.
    NOTE
    A new front axle wheel hub retaining nut must be installed.

  8.  
  9. Manually thread the front axle wheel hub retaining nut onto the outboard CV-joint stub shaft housing as far as possible.
    NOTE
    A new bolt and nut must be used to connect the front suspension arm to the knuckle.

  10.  
  11. Connect the front suspension lower arm to the front wheel knuckle. Tighten the nut and bolt to 46 ft. lbs. (63 Nm).
  12.  
  13. Install the front brake anti-lock sensor.
    NOTE
    Do not use power or impact tools to tighten the hub nut.

  14.  
  15. Tighten front axle wheel hub retaining nut to 111ft. lbs. (150 Nm).
  16.  
  17. Install the front wheels and lower the vehicle.
  18.  
  19. Fill the transaxle to the proper level with Mercon®V automatic transmission fluid.
  20.  

 
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