Ford Model Rear and Front Halfshafts Removal Procedure?

Front and Rear Halfshaft Removal procedure is for
Lincoln Aviator, Ford Explorer, Exp Sport, Exp Sport-Trac, Mercury Mountaineer 2000-2005.


Removal & Installation
FRONT
REAR

The instructions with proper details and diagrams are mentioned below.

1. Before servicing the vehicle, refer to the Precautions section.
2. Remove or disconnect the following:
   
   
   Negative battery cable

   Front wheel

   Manual locking hub assembly from the rotor by pulling straight outward

   Plastic stub shaft retainer

   Front disc brake caliper from the anchor and move it aside. Support the front suspension lower arm.

   Upper ball joint from the steering knuckle

   Outboard front driveshaft from the hub

   Halfshaft from the axle housing

   Driveshaft and joint from the axle housing

To install:

1. Install or connect the following:
   
   
   Halfshaft and joint to the axle housing

   Outboard front driveshaft to the hub

   Upper ball joint to the steering knuckle

   Brake caliper to the anchor and remove the front suspension support

   New stub shaft retainer

   Locking hub to the brake rotor

   Front wheel

   Negative battery cable

Front

Fig. Front axle halfshaft

1. Before servicing the vehicle, please familiarize yourself with safety procedures.
2. Remove or disconnect the following:
3. Loosen the front axle wheel hub retainer.
   
   WARNING

   Do not allow the knuckle to hang freely. It is possible to overextend and internally separate each inner CV-joint from its housing.
   
   
   
   WARNING

   Do not use a hammer to separate the outboard CV-joint from the hub. Damage to the threads and internal CV-joint components may result.
   
   
   
   
   Wheel and tire assembly

   Hub retainer and the washer. Discard the front axle wheel hub retainer.

   The two bolts and position the disc brake caliper aside

   Tie-rod end from the knuckle. Discard the nut.

   Stabilizer bar link. Discard the nut.
   
   
   
   
   Upper ball joint from the knuckle
4. Press the outboard CV-joint until it is loose in the hub.
5. Remove the outboard CV-joint from the hub.
   
   WARNING

   Do not damage the axle shaft oil seal or the machined sealing surface on the inboard CV-joint housing.
   
   
   
   NOTE

   A circlip retains the inboard CV-joint housing to the differential side gear in the axle.
6. On the left side, pry the left inboard CV-joint housing from the differential side gear.
7. On the right side, disengage the right inboard CV-joint housing from the axle tube.
8. Pull the halfshaft and the axle shaft away from the axle tube, and separate the inboard CV-joint housing from the axle shaft.
9. Remove the halfshaft assembly from the vehicle.
   
   WARNING

   Do not damage the axle shaft oil seal, the machined sealing surface on the inboard CV-joint housing, or the axle shaft splines.

To install:

1. Installation is the reverse of the removal procedure.
2. Always install the halfshaft with a new retainer circlip and a new front axle wheel hub retainer.
3. On the right side, check the retainer circlip engagement after reseating the axle shaft and after installing the halfshaft in the axle. On the left side, check the retainer circlip engagement after installing the halfshaft in the axle. When seated, the retainer circlip will lock the axle shaft and the inboard CV-joint housing to the axle.
   
   WARNING

   Never use power tools to tighten the front axle wheel hub retainer. Torque the retainer to 184 ft. lbs. (250 Nm).
   
   
   
   NOTE

   It may be necessary to support the front suspension lower arm to be able to connect the upper ball joint to the knuckle.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Remove or disconnect the following:
3. Loosen the front axle wheel hub retainer.
   
   WARNING

   Do not allow the knuckle to hang freely. It is possible to overextend and internally separate each inner CV joint from its housing.
   
   
   
   WARNING

   Do not use a hammer to separate the outboard CV joint from the hub. Damage to the threads and internal CV joint components may result.
   
   
   
   
   Wheel and tire assembly

   Hub retainer and the washer. Discard the front axle wheel hub retainer.

   The two bolts and position the disc brake caliper aside

   Tie-rod end from the knuckle. Discard the nut.

   Stabilizer bar link. Discard the nut.
   
   
   
   
   Upper ball joint from the knuckle
4. Press the outboard CV joint until it is loose in the hub.
5. Remove the outboard CV joint from the hub.
   
   WARNING

   Do not damage the axle shaft oil seal or the machined sealing surface on the inboard CV joint housing.
   
   
   
   NOTE

   A circlip retains the inboard CV joint housing to the differential side gear in the axle.
6. On the left side, pry the LH inboard CV joint housing from the differential side gear.
7. On the right side, disengage the RH inboard CV joint housing from the axle tube.
8. Pull the halfshaft and the axle shaft away from the axle tube, and separate the inboard CV joint housing from the axle shaft.
9. Remove the halfshaft assembly from the vehicle.
   
   WARNING

   Do not damage the axle shaft oil seal, the machined sealing surface on the inboard CV joint housing, or the axle shaft splines.
10. To install, reverse the removal procedure.
11. Always install the halfshaft with a new retainer circlip and a new front axle wheel hub retainer.
12. On the right side, check the retainer circlip engagement after reseating the axle shaft and after installing the halfshaft in the axle. On the LH side, check the retainer circlip engagement after installing the halfshaft in the axle. When seated, the retainer circlip will lock the axle shaft and the inboard CV joint housing to the axle.
    
    WARNING

    Never use power tools to tighten the front axle wheel hub retainer. Torque the retainer to 184 ft. lbs. (250 Nm).
    
    
    
    NOTE

    It may be necessary to support the front suspension lower arm to be able to connect the upper ball joint to the knuckle.

Rear

Fig. Rear axle halfshaft

1. Before servicing the vehicle, please familiarize yourself with safety procedures.
2. Remove or disconnect the following:
   
   WARNING

   Do not loosen the rear axle wheel hub retainer until after the wheel and tire assembly are removed from the vehicle. Wheel bearing damage will occur if the wheel bearing is unloaded with the weight of the vehicle applied.
   
   
   
   NOTE

   Have an assistant press the brake pedal to keep the axle from rotating.
   
   
   
   WARNING

   Using a rubber hose approximately 37.5 mm (1.5 in) long, cover the stabilizer link bolt threads and nut to prevent boot damage when removing the halfshaft assembly from the vehicle.
   
   
   
   WARNING

   The bolt that retains the upper ball joint to the knuckle is longer and it has fewer threads than the bolt that retains the toe link to the knuckle. Switching these bolts during installation will prevent the pinch arms on the knuckle from correctly retaining the toe link to the knuckle. This may cause the toe link to separate from the knuckle during vehicle operation. Failure to follow these instructions may result in personal injury.
   
   
   
   WARNING

   Using a wood stick, approximately 450 mm (18 in) long and 25 mm (1 in) wide, support the rear suspension upper arm to prevent boot damage when removing the halfshaft assembly from the vehicle
   
   
   
   NOTE

   Do not use a hammer to separate the outboard CV-joint from the hub. Damage to the threads and internal CV-joint components may result. Once the outboard CV-joint separates from the hub the knuckle will continue to pivot until the brake backing plate presses against the suspension lower arm. To prevent damage to the brake backing plate, immediately after separating the outboard CV-joint from the hub, rest the knuckle on a cushioned support that is tall enough to keep the backing plate from pressing against the suspension lower arm.
   
   
   
   
   Wheel and tire assembly
   
   
   
   
   Hub retainer and the washer

   Caliper. Position the disc brake caliper out of the way.

   Brake disc

   Bolt retaining the parking brake cable bracket to the frame
   
   
   
   
   Pinch bolts and disconnect the toe link and upper ball joint from the knuckle
   
   
   
   
   

   

   Fig. Using a wood stick, approximately 450 mm (18 in) long and 25 mm (1 in) wide, support the rear suspension upper arm to prevent boot damage when removing the halfshaft assembly from the vehicle
3. Press the outboard CV-joint until it is loose in the hub.
4. Separate the outboard CV-joint from the hub.
5. Rest the knuckle on a cushioned support.
   
   WARNING

   Do not damage the axle shaft oil seal or the machined sealing surface on the inboard CV-joint housing.
   
   
   
   NOTE

   A circlip retains the inboard CV-joint housing to the differential side gear in the axle.
6. Using the special tool, disengage the inboard CV-joint housing from the differential side gear.
   
   WARNING

   To prevent damage to the axle shaft oil seal, install the special tool 205-461 (seal protector) before removing the inboard CV-joint housing from the axle.
7. Remove the halfshaft assembly from the vehicle.

To install:

1. Installation is the reverse of the removal procedure.
2. To prevent damage to the axle shaft oil seal, install the seal protector before positioning the inboard CV-joint housing in the axle.
3. Always install the halfshaft with a new retainer circlip and a new rear axle wheel hub retainer.
   
   NOTE

   Never use power tools to tighten the rear axle wheel hub retainer. Torque the retainer to 203 ft. lbs. (275 Nm).

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Remove or disconnect the following:
   
   WARNING

   Do not loosen the rear axle wheel hub retainer until after the wheel and tire assembly are removed from the vehicle. Wheel bearing damage will occur if the wheel bearing is unloaded with the weight of the vehicle applied.
   
   
   
   NOTE

   Have an assistant press the brake pedal to keep the axle from rotating.
   
   
   
   WARNING

   Using a rubber hose approximately 37.5 mm (1.5 in) long, cover the stabilizer link bolt threads and nut to prevent boot damage when removing the halfshaft assembly from the vehicle.
   
   
   
   WARNING

   The bolt that retains the upper ball joint to the knuckle is longer and it has fewer threads than the bolt that retains the toe link to the knuckle. Switching these bolts during installation will prevent the pinch arms on the knuckle from correctly retaining the toe link to the knuckle. This may cause the toe link to separate from the knuckle during vehicle operation. Failure to follow these instructions may result in personal injury.
   
   
   
   WARNING

   Using a wood stick, approximately 450 mm (18 in) long and 25 mm (1 in) wide, support the rear suspension upper arm to prevent boot damage when removing the halfshaft assembly from the vehicle.
   
   
   
   NOTE

   Do not use a hammer to separate the outboard CV joint from the hub. Damage to the threads and internal CV joint components may result. Once the outboard CV joint separates from the hub the knuckle will continue to pivot until the brake backing plate presses against the suspension lower arm. To prevent damage to the brake backing plate, immediately after separating the outboard CV joint from the hub, rest the knuckle on a cushioned support that is tall enough to keep the backing plate from pressing against the suspension lower arm.
   
   
   
   
   Wheel and tire assembly
   
   
   
   
   Hub retainer and the washer

   Caliper. Position the disc brake caliper out of the way.

   Brake disc

   Bolt retaining the parking brake cable bracket to the frame
   
   
   
   
   Pinch bolts and disconnect the toe link and upper ball joint from the knuckle
3. Press the outboard CV joint until it is loose in the hub.
4. Separate the outboard CV joint from the hub.
5. Rest the knuckle on a cushioned support.
   
   WARNING

   Do not damage the axle shaft oil seal or the machined sealing surface on the inboard CV joint housing.
   
   
   
   NOTE

   A circlip retains the inboard CV joint housing to the differential side gear in the axle.
6. Using the special tool, disengage the inboard CV joint housing from the differential side gear.
   
   WARNING

   To prevent damage to the axle shaft oil seal, install the special tool 205-461 (seal protector) before removing the inboard CV joint housing from the axle.
7. Remove the halfshaft assembly from the vehicle.
8. To install, reverse the removal procedure.
9. To prevent damage to the axle shaft oil seal, install the seal protector before positioning the inboard CV joint housing in the axle.
10. Always install the halfshaft with a new retainer circlip and a new rear axle wheel hub retainer.
    
    NOTE

    Never use power tools to tighten the rear axle wheel hub retainer. Torque the retainer to 251 ft. lbs. (340Nm).

This will help.
Thanks.

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Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html