Output Shaft: Service and Repair

Removal





Special Service Tools

1. Raise and support the vehicle.
2. Remove the intermediate muffler.





3. Remove the bolts and the center heat shield.

4. CAUTION: The transmission flange bolts, nuts, and washers must be removed as matched sets and installed in the original locations. The system balance add-on nuts must be installed in the original locations.

CAUTION: Under no circumstances must the flexible coupling (or its fixings) be loosened or removed from the driveshaft.

Note: Make sure to disconnect the coupling from the transmission flange only.





Detach the transmission flexible joint.
- Using different color paint markers, place index matchmarks on the transmission flange, driveshaft flexible coupling and the transmission bolts, nuts, washers and add-on nuts, so the driveshaft and the transmission flange can be aligned correctly during installation.





5. Note: Support the front section of the driveshaft.
Shorten the length of the driveshaft.
- Using the special tool, loosen the driveshaft locknut and move the driveshaft front section towards the center bearing.
6. Remove the output shaft flange nut.
7. Remove the output shaft flange.





8. Remove the output shaft oil seal.

Installation





1. Install the output shaft oil seal.
2. Install the output shaft flange.
- Stage 1: tighten the nut to 170 Nm (125 ft. lbs.).
- Stage 2: loosen the nut by 1/2 turn.
- Stage 3: tighten the nut to 120 Nm (89 ft. lbs.).
3. Install the output shaft nut.

4. Note: Install one gram of Premium Long Life Grease, XG-1-K or equivalent meeting Ford specifications ESA-M1C75-B, in the alignment bushing prior to installation.

Slide the driveshaft forward until the flexible coupling engages the transmission flange.





5. CAUTION: Make sure to match the bolts, washers, attaching nuts and balance nuts (if equipped) to their original locations.

CAUTION: Tighten the transmission flange bolts and nuts with hand tools only.

Note: Align the driveshaft index matchmarks.

Install the flex coupling bolts, washers and attaching nuts.





6. Using the special tools, tighten the driveshaft yoke nuts.





7. Install the bolts and the center heat shield.
8. Lower the vehicle.