How to Replace Front Drive Axle Halfshafts?

The details to replace Halfshafts are for Ford and Mercury car model.


Halfshafts
REMOVAL & INSTALLATION
Instructions are as follows :-----

Left Side

Specific to:

Ford Taurus 2008-2009

Mercury Sable 2008-2009

1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the front tire and wheel.
   
   NOTE

   Apply the brake to keep the halfshaft from rotating.
3. Remove the front wheel hub nut. Do not discard at this time.
   
   NOTE

   Do not allow the ball joint stud to contact the CV boot.
4. Remove the ball joint nut and separate the lower control arm from the knuckle.
5. Using the Front Wheel Hub Remover, separate the halfshaft from the wheel hub.
   
   NOTE

   Support the knuckle with a suitable jackstand.
6. Pull the knuckle outboard and rotate it toward the rear of the vehicle.
   
   NOTE

   The sharp edges on the stub shaft splines can slice or puncture the oil seal. Use care when inserting the stub shaft into the transmission or damage to the component may occur.
7. Using the Slide Hammer and Halfshaft Remover, remove the halfshaft from the transmission.
8. Remove and discard the circlip from the stub shaft.

To install:

NOTE

The circlips are unique in size and shape for each shaft. Make sure to use the specified circlip for the application or vehicle damage may occur.

1. Install the correct new circlip on the inboard stub shaft.
   
   NOTE

   After insertion, pull the halfshaft inner end to make sure the circlip is locked.
2. Push the stub shaft into the transmission so the circlip locks into the differential side gear.
3. Insert the halfshaft into the wheel hub.
4. Rotate the knuckle into position.
5. Position the ball joint in the knuckle and install the ball joint nut. Tighten to 81 ft. lbs. (110 Nm).
   
   NOTE

   Do not tighten the front wheel hub nut with the vehicle on the ground. The nut must be tightened to specification before the vehicle is lowered onto the wheels. Wheel bearing damage will occur if the wheel bearing is loaded with the weight of the vehicle applied.
   
   
   
   NOTE

   Apply the brake to keep the halfshaft from rotating.
6. Using the previously removed hub nut, seat the halfshaft. Tighten to 258 ft. lbs. (350 Nm).
7. Remove and discard the hub nut.
   
   NOTE

   The wheel hub nut contains a one-time locking chemical that is activated by the heat created when it is tightened. Install and tighten the new wheel hub nut to specification within 5 minutes of starting it on the threads. Always install a new wheel hub nut after loosening or when not tightened within the specified time or damage to the components can occur.
   
   
   
   NOTE

   Apply the brake to keep the halfshaft from rotating.
8. Install a new hub nut. Tighten to 258 ft. lbs. (350 Nm).
9. Install the front tire and wheel.

Right Side

Specific to:

Ford Taurus 2008-2009

Mercury Sable 2008-2009

1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the front tire and wheel.
   
   NOTE

   Apply the brake to keep the halfshaft from rotating.
3. Remove the front wheel hub nut. Do not discard at this time.
4. On All-Wheel Drive (AWD) vehicles, remove the RH brake disc.
5. On all vehicles, remove the bolt from the brake tube bracket.
   
   NOTE

   Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part number or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts.
   
   
   
   NOTE

   Do not allow the ball joint stud to contact the CV boot.
6. Remove and discard the ball joint nut.
7. Separate the lower control arm from the knuckle.
8. Using the Front Wheel Hub Remover, separate the halfshaft from the wheel hub.
9. Pull the knuckle outboard and rotate it toward the rear of the vehicle.
10. Secure the knuckle assembly.
11. Remove the 2 lower scrivets from the rubber shield and position the shield aside.
12. Remove the 2 intermediate shaft bracket nuts.
13. Remove the halfshaft assembly.
14. Inspect the intermediate shaft for pitting or damage in the seal contact area. Replace if necessary.

To install:

1. On All-Wheel Drive (AWD) vehicles, a new Power Transfer Unit (PTU) shaft seal must be installed whenever the intermediate shaft is removed or damage to the components can occur.
2. Install a new intermediate shaft seal and deflector.
3. On all vehicles, install the intermediate and halfshaft assembly and the 2 nuts. Tighten to 18 ft. lbs. (25 Nm).
4. Position the halfshaft and ball joint into the wheel knuckle. Install the new ball joint nut. Tighten to 111 ft. lbs. (150 Nm).
5. Install the bolt in the brake tube bracket. Tighten to 22 ft. lbs. (30 Nm).
6. Install the 2 scrivets in the rubber shield.
7. On All-Wheel Drive (AWD) vehicles, install the RH brake disc.
8. On all vehicles, Do not tighten the front wheel hub nut with the vehicle on the ground. The nut must be tightened to specification before the vehicle is lowered onto the wheels. Wheel bearing damage will occur if the wheel bearing is loaded with the weight of the vehicle applied.
   
   NOTE

   Apply the brake to keep the halfshaft from rotating.
9. Using the previously removed hub nut, seat the halfshaft. Tighten to 258 ft. lbs. (350 Nm).
10. Remove and discard the hub nut.
    
    NOTE

    The wheel hub nut contains a one-time locking chemical that is activated by the heat created when it is tightened. Install and tighten the new wheel hub nut to specification within 5 minutes of starting it on the threads. Always install a new wheel hub nut after loosening or when not tightened within the specified time or damage to the components can occur.
    
    
    
    NOTE

    Apply the brake to keep the halfshaft from rotating.
11. Install a new hub nut. Tighten to 258 ft. lbs. (350 Nm).
12. Install the front tire and wheel.

This should help.

Thanks.

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Car repair guide?

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