Fusion FWD V6-3.0L (2009)
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equipped with nylon thrust washers located at the base of each bearing cup which control end play, position the needle bearings and improve
grease movement.
Rear Drive Unit
The active torque coupling/Rear Drive Unit (RDU) is serviced as an assembly.
The RDU housing cover uses a silicone sealant rather than a gasket.
Each halfshaft is held in the RDU case by a halfshaft circlip that is located on the inner CV joint stub shaft pilot bearing housing. When each halfshaft is
installed, the halfshaft circlip engages a slot in the differential side gear.
The RDU operates as follows:
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The RDU pinion receives power from the engine through the transaxle, PTU, driveshaft and active torque coupling, and is always engaged.
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The pinion gear rotates the differential case, which is bolted to the differential case outer flange.
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Inside the differential case, 2 differential pinion gears are mounted on a differential pinion shaft that is pinned to the differential case.
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These differential pinion gears are engaged with the differential side gears, to which the halfshafts are splined.
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As the differential case turns, it rotates the halfshafts and rear wheels.
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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.
Halfshafts
The drive halfshafts consist of the following components:
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Inner CV joints
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Outer CV joints
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CV joint boot clamps
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CV joint boots
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Tripod joint housings
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Retainer circlips
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Front intermediate shaft bearing
The front intermediate shaft bearing is pressed on and is only serviced as an assembly with the intermediate shaft.
NOTICE: An inspection of the outer and inner constant velocity (CV) joint boots is necessary so that if damage or grease leakage is evident,
installation of a new halfshaft can take place immediately. Continued operation with damage or grease leakage will result in CV joint wear and
noise due to contamination and loss of the CV joint grease.
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The inner and outer CV joints connect to a splined shaft. A circlip holds the cross groove inner race assembly (inner CV joint) together.
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A circlip retains the splined inner CV joint. Install a new axle circlip each time the halfshaft is removed from the vehicle.
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A wheel hub nut secures the side shaft assembly (interconnecting shaft and outer CV joint) to the wheel hub. Install a new wheel hub nut each time
the halfshaft is removed from the vehicle.
Halfshaft Handling
NOTICE: Handle the halfshaft only by the interconnecting shaft to avoid pull-apart and potential damage to the constant velocity (CV) joints.
Damage will occur to an assembled inner CV joint if it is over-plunged outward from the joint housing or over angled.
Handle all halfshaft components carefully during removal and installation procedures. Never use a hammer to remove or install the halfshafts. Never use
the halfshaft assembly as a lever to position other components. Always support the free end of the halfshaft. Do not allow the boots to contact sharp
edges or hot exhaust components. Do not drop assembled halfshafts. The impact may cut the boots from the inside without evidence of external damage.
