HOW TO PULL THE AXLES FROM A 1996 FORD ESCORT WITH 1.8 ...

REMOVAL & INSTALLATION

1991-96 Models

1.9L Engine and Left Side OF 1.8L Engine

See Figures 1 through 19

Before continuing with any halfshaft procedure, make sure to have available, new halfshaft retaining nuts and circlips. Once removed, these parts loose their torque holding ability or retention capability and must not be reused.

1. Disconnect the negative battery cable.

2. With the vehicle sitting on the ground, carefully raise the staked portion of the halfshaft retaining nut using a suitable small chisel. Loosen the nut.

3. Raise and safely support the vehicle.

4. Remove the wheel and tire assembly.

5. Remove the splash shield.

6. Remove and discard the halfshaft retaining nut.

7. Remove the cotter pin and castellated nut from the tie rod end, and separate the tie rod end from the steering knuckle using a suitable removal tool. Discard the cotter pin.

8. In some cases, it may be necessary to remove the sway bar nut before prying down on the control arm.

9. Remove the lower ball joint pinch bolt. Carefully pry down on the lower control arm to separate the ball joint stud from the steering knuckle.

10. Pull outward on the steering knuckle/brake assembly. Carefully pull the halfshaft from the hub and position it aside.

11. Removal of the left side halfshaft requires removal of the crossmember to allow access with a prybar as follows:

    1. Support the transaxle with a suitable transaxle jack.

    2. Remove the four transaxle mount-to-crossmember retaining nuts.

    3. Remove the two crossmember retaining nuts at the rear of the crossmember.

    4. While supporting the rear of the crossmember, unfasten the two front mounting bolts and remove the crossmember.

12. Position a drain pan under the transaxle.

13. Insert a prybar between the halfshaft and the transaxle case. Gently pry outward to release the halfshaft from the differential side gear. Be careful not to damage the transaxle case, oil seal, CV-joint or CV-joint boot.

14. Remove the halfshaft.

Install suitable plug(s) after removing the halfshaft(s) to prevent the differential side gears from moving out of place. Should the gears become misaligned, the differential will have to be removed from the transaxle to align the gears.

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Fig. 1: With the vehicle on the ground, carefully raise the staked portion of the halfshaft retaining nut with a small chisel

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Fig. 2: Loosen the halfshaft retaining nut

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Fig. 3: Remove and discard the halfshaft retaining nut

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Fig. 4: Remove the cotter pin from the tie rod end

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Fig. 5: Loosen, but do not remove the tie rod end's castellated nut

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Fig. 6: Separate the tie rod end from the steering knuckle using a suitable removal tool

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Fig. 7: Remove the castellated nut and disengage the tie rod end from the steering knuckle

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Fig. 8: In some cases, it may be necessary to loosen the sway bar nut ...

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Fig. 9: ... then remove the nut, washer and bushing. This will make it easier to separate the ball joint stud

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Fig. 10: Unfasten the lower ball joint pinch bolt ...

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Fig. 11: ... then remove the pinch bolt and nut

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Fig. 12: Carefully pry down on the lower control arm to separate the ball joint stud from the steering knuckle

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Fig. 13: Pull outward on the steering knuckle/brake assembly. Separate the hub from the halfshaft and position it aside

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Fig. 14: Insert a prybar between the halfshaft and transaxle case. Gently pry outward to release the halfshaft from the differential side gear

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Fig. 15: Place a drain pan beneath the transaxle to catch any fluid that could drain from the transaxle during halfshaft removal

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Fig. 16: Remove the halfshaft from the vehicle ...

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Fig. 17: ... and install a suitable plug to prevent the differential side gears from moving out of place

To install:

15. Position a new circlip on the inner CV-joint spline so the circlip gap is at the top. Lubricate the splines lightly with a suitable grease.

16. Remove the plugs that were installed in the differential side gears.

17. Position the halfshaft so the CV-joint splines are aligned with the differential side gear splines. Push the halfshaft into the differential. When seated properly, the circlip can be felt snapping into the differential side gear groove.

18. Pull outward on the steering knuckle/brake assembly and insert the halfshaft into the hub.

19. Pry downward on the lower control arm and position the lower ball joint stud in the steering knuckle.

20. Install the crossmember and the crossmember-to-frame nuts and bolts. Tighten the nuts to 27-38 ft. lbs. (37-52 Nm) and the bolts to 47-66 ft. lbs. (64-89 Nm).

21. Install the four transaxle mount-to-crossmember nuts and tighten to 27-38 ft. lbs. (37-52 Nm).

22. Remove the transaxle jack.

23. Install the lower ball joint pinch bolt and tighten to 32-43 ft. lbs. (43-59 Nm).

24. Attach the tie rod end to the steering knuckle. Install the castellated nut and tighten to 31-42 ft. lbs. (42-57 Nm). Install a new cotter pin.

25. If removed, attach the sway bar nut and tighten to specification.

26. Install the splash shield.

27. Install the wheel and tire assembly.

28. Install a new halfshaft retaining nut and tighten to 174-235 ft. lbs. (235-319 Nm). Stake the halfshaft retaining nut using a suitable chisel with a rounded cutting edge.

If the nut splits or cracks after staking, replace it with a new nut.

29. Check and refill the transaxle with the proper type and quantity of fluid.

30. Connect the negative battery cable.

31. Road test the vehicle and check for proper operation.

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Fig. 18: Remove the old circlip from the inner CV-joint spline, then install a new circlip with the gap at the top

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Fig. 19: Exploded view of a typical halfshaft assembly-1991-96 models

Right Side OF 1.8L Engine

The right side halfshaft assembly is a two piece shaft with a bearing support bracket positioned between the two halves. The bearing support bracket is mounted on the cylinder block and must be unbolted if the entire halfshaft assembly is to be removed. If only the CV-joints/boots are to be serviced, the outboard shaft assembly may be removed, leaving the bearing support bracket mounted on the engine cylinder block.

1. Disconnect the negative battery cable.

2. With the vehicle sitting on the ground, carefully raise the staked portion of the halfshaft retaining nut using a suitable small chisel. Loosen the nut.

3. Raise and safely support the vehicle.

4. Remove the right front wheel and tire assembly.

5. Remove the splash shield.

6. Remove and discard the halfshaft retaining nut.

7. Remove the cotter pin and castellated nut from the tie rod end and separate the tie rod end from the steering knuckle using a suitable removal tool. Discard the cotter pin.

8. Remove the lower ball joint pinch bolt. Carefully pry down on the lower control arm to separate the ball joint stud from the steering knuckle.

9. Pull outward on the steering knuckle/brake assembly. Carefully pull the halfshaft from the hub and position it aside.

10. Position a drain pan under the transaxle.

11. Remove the three bearing support bracket mounting bolts.

12. Insert a prybar between the bearing support bracket and the starter bracket. Gently pry outward on the damper until the halfshaft disengages from the differential side gear.

13. Remove the halfshaft assembly. Install an appropriate differential plug in the differential side gear.

To install:

14. Position a new circlip on the inner CV-joint spline so the circlip gap is at the top. Lubricate the splines lightly with a suitable grease.

15. Remove the differential plug from the side gear. Position the halfshaft assembly so the shaft splines are aligned with the differential side gear splines. Push the halfshaft into the differential. When seated properly, the circlip can be felt snapping into the differential side gear groove.

16. Pull outward on the steering knuckle/brake assembly and insert the halfshaft into the hub.

17. Pry downward on the lower control arm and position the lower ball joint stud into the steering knuckle. Install the lower ball joint pinch bolt and tighten to 32-43 ft. lbs. (43-59 Nm).

18. Install the tie rod end to the steering knuckle. Install the castellated nut and tighten to 31-42 ft. lbs. (42-57 Nm). Install a new cotter pin.

19. Position the bearing support bracket and install the three retaining bolts. Tighten the outer bolt first, then the top inner, then the bottom inner. Tighten the bolts to 31-46 ft. lbs. (42-62 Nm).

20. Install the splash shield.

21. Install the wheel and tire assembly.

22. Lower the vehicle.

23. Install a new halfshaft retaining nut and tighten to 174-235 ft. lbs. (235-319 Nm). Stake the retaining nut using a suitable chisel with the cutting edge rounded off.

If the nut splits or cracks after staking, it must be replaced with a new nut.

24. Check and refill the transaxle with the proper type and quantity of fluid.

25. Connect the negative battery cable.

26. Road test the vehicle and check for proper operation.

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