Ford Taurus Service Manual: Rear Drive Axle/Differential

SPECIFICATIONS

Material

Ford Taurus. Driveline

Torque Specifications

Ford Taurus. Driveline

DESCRIPTION AND OPERATION

Rear Drive Axle and Differential

The rear drive axle consists of the following components:

  • Dished circular flange
  • Full-time Active Torque Coupling (ATC)
  • Aluminum housing with steel housing cover
  • Matched ring and pinion
  • Conventional open differential
  • Rubber bushing isolated mounting points
  • Cover-mounted axle vent

The rear axle drive pinion receives power from the engine through the transaxle, Power Transfer Unit (PTU), driveshaft and ATC, and is always engaged. The All-Wheel Drive (AWD) system on this vehicle is equipped with a bar-coded rear axle to reduce the tolerance of electrical current-to-torque delivered by the ATC. The 4X4 control module uses this bar code information to match the clutch characteristics of the ATC with the desired output torque. The pinion gear then rotates the differential ring gear, which is bolted to the differential case outer flange. Inside the differential case, 2 differential pinion gears are mounted on a differential pinion shaft, which is pinned to the differential case. These differential pinion gears are engaged with the differential side gears to which the halfshafts are splined. The halfshafts are held in the differential case by a driveshaft bearing retainer circlip that is located on the inboard CV joint stub shaft pilot bearing housing. When each halfshaft is installed, the driveshaft bearing retainer circlip engages a step in the differential side gear. As the differential case turns, it rotates the halfshafts and rear wheels. When it is necessary for one wheel and halfshaft to rotate faster than the other, the faster turning differential side gear causes the differential pinion gears to roll on the slower turning differential side gear. This allows differential action between the 2 halfshafts. The pinion seal and the differential halfshaft seals are the only serviced components of the rear drive axle. There are no stub shaft bearings in the differential housing and the differential housing cover uses a silicone sealant rather than a gasket. If other components of the rear drive axle or the ATC are worn or damaged, a new axle assembly must be installed.

IN-VEHICLE REPAIR

Drive Pinion Seal

Special Tool(s)

Ford Taurus. Driveline

Material

Ford Taurus. Driveline

Ford Taurus. Driveline

Ford Taurus. Driveline

Removal

  1. Remove the driveshaft. For additional information, refer to Section 205-01.
  1. Using the Drive Pinion Flange Holding Fixture, hold the pinion flange and remove the nut.
    • Discard the nut.

    Ford Taurus. Driveline

  1. Index-mark the location of the pinion to the yoke.

    Ford Taurus. Driveline

  1. Using the 2 Jaw Puller, remove the pinion flange.

    Ford Taurus. Driveline

  1. Using the Torque Converter Fluid Seal Remover and Slide Hammer, remove the seal.

    Ford Taurus. Driveline

Installation

  1. NOTE: Make sure that the mating surface is clean before installing the new seal.

    Using the Pinion Seal Replacer, install the seal.

    Ford Taurus. Driveline

  1. NOTE: Lubricate the pinion flange with grease.

    Line up the index marks and position the pinion flange.

    Ford Taurus. Driveline

  1. Using the Drive Pinion Flange Holding Fixture, install the new pinion nut.
    • Tighten to 244 Nm (180 lb-ft).

    Ford Taurus. Driveline

  1. Install the driveshaft. For additional information, refer to Section 205-01.

Stub Shaft Seal

Special Tool(s)

Ford Taurus. Driveline

Material

Ford Taurus. Driveline

Ford Taurus. Driveline

Ford Taurus. Driveline

Removal

NOTE: The Rear Drive Unit (RDU) does not have stub shaft pilot bearings. It has stub shaft seals only.

  1. Remove the halfshaft assembly. For additional information, refer to Section 205-05.
  1. Using the Torque Converter Fluid Seal Remover and Slide Hammer, remove the stub shaft seal.

    Ford Taurus. Driveline

Installation

  1. NOTE: Lubricate the new stub shaft seal with grease.

    Using the Front Axle Oil Seal Installer and Handle, install the stub shaft pilot bearing housing seal.

    Ford Taurus. Driveline

  1. Install the halfshaft assembly. For additional information, refer to Section 205-05.

Differential Housing Cover

Material

Ford Taurus. Driveline

Ford Taurus. Driveline

Ford Taurus. Driveline

Removal

  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02.
  1. If equipped, remove the exhaust insulator located near the differential housing cover using soapy water.
  1. NOTE: Drain the differential fluid into a suitable drain pan.

    Remove the 10 bolts and the rear differential housing cover.

    • Drain the differential fluid from the housing.

Installation

  1. NOTE: Make sure the machined surfaces on the rear axle housing and the differential housing cover are clean and free of oil before installing the new silicone sealant. The inside of the rear axle must be covered when cleaning the machined surface to prevent contamination.

    Clean the gasket mating surfaces of the differential housing and the differential housing cover.

  1. NOTE: The differential housing cover must be installed within 15 minutes of application of the silicone, or new silicone must be applied. If possible, allow one hour before filling with lubricant to make sure the silicone has correctly cured.

    Apply a new continuous bead of clear silicone rubber as shown in the illustration.

    Ford Taurus. Driveline

  1. Install the differential housing cover and the 10 bolts.
    • Tighten to 23 Nm (17 lb-ft).
  1. Remove the filler plug and fill the rear axle with 1.15L (2.43 pt) of rear axle lubricant, 3-5 mm (0.118-0.196 in) below the bottom of the filler hole.
    • Install the filler plug and tighten to 29 Nm (21 lb-ft).
  1. If equipped, install the exhaust insulator located near the differential housing cover.

REMOVAL AND INSTALLATION

Axle Assembly

Special Tool(s)

Ford Taurus. Driveline

Ford Taurus. Driveline

Ford Taurus. Driveline

Removal

  1. Remove the driveshaft assembly. For additional information, refer to Section 205-01.
  1. Remove the rear halfshafts. For additional information, refer to Section 205-05.
  1. Remove the stabilizer bar. For additional information, refer to Section 204-02.
  1. Position a suitable transmission hydraulic jack to the axle housing.
    • Securely strap the jack to the housing.
  1. Remove the 4 differential housing-to-front insulator bracket bolts.
  1. Remove the 6 side insulator bracket-to-rear axle differential bolts.
  1. Lower the axle to gain clearance to the Active Torque Coupling (ATC) electrical connector and disconnect the connector.
  1. Remove the axle assembly.

Installation

  1. NOTICE: If replacing the axle assembly, the 4X4 control module will need to be reconfigured with the new Active Torque Coupling (ATC) bar code information. If the new bar code information does not match the existing 4X4 control module information, driveline damage or driveability concerns can occur.

    NOTE: The ATC bar code can be found etched on the ATC wire harness connector of the new axle assembly.

    Record the bar code identification number from the new axle assemblies wire harness connector.

    Ford Taurus. Driveline

  1. Position the axle housing on a suitable transmission hydraulic jack.
    • Securely strap the jack to the housing.
  1. Raise the axle and connect the ATC electrical connector.
  1. Install the 6 side insulator bracket-to-rear axle differential bolts.
    • Tighten to 90 Nm (66 lb-ft).
  1. Install the 4 differential housing-to-front insulator bracket bolts.
    • Tighten to 90 Nm (66 lb-ft).
  1. Install the stabilizer bar. For additional information, refer to Section 204-02.
  1. Install the rear halfshafts. For additional information, refer to Section 205-05.
  1. Install the driveshaft assembly. For additional information, refer to Section 205-01.
  1. If a new RDU was installed, re-configure the Automatic Torque Coupling (ATC). Refer to Section 308-07A.
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