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Front Drive Halfshafts - Front Halfshaft RH Focus 2004.75 (07/2004-)
Removal and Installation

Special Tool(s)

Protector, Ball Joint Gaiter

204-349

Protector, Halfshaft Seal

205-775

General Equipment
Ball joint separator
Materials
Name
Specification
Silicone Grease
ESE-M1C171-A 
Transmission Fluid
WSD-M2C200-C 

Removal

  1. Remove the wheel and tire.
    For additional information, refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).

  1. Remove the wheel hub retaining bolt.
    • Discard the wheel hub retaining bolt.
  1. NOTE:
    NOTE:Use a suitable brass drift if necessary.
    Push the halfshaft into the tripode housing as far as the stop (approximately 20 mm).

  1. Detach the headlamp leveling sensor bracket from the lower arm and secure it to one side (if equipped).

  1. Remove the crashbox.

  1. Using the special tool to prevent the ball joint stud from rotating, remove and discard the lower arm ball joint retaining nut.

  1. CAUTION:
    CAUTION:Make sure the special tool is installed with the curved surface facing upwards to prevent damage to the ball joint seal.
    Install the special tool.

  1. CAUTION:
    CAUTION:Make sure the strut and spring assembly does not move in a forwards or rearwards direction, to prevent damage to the top mount center cup.
    Using a suitable ball joint separator, detach the lower arm from the wheel knuckle.
    • Remove the special tool.
  1. CAUTION:
    CAUTION:The inner constant velocity (CV) joint must not be bent more than 23 degrees. The outer CV joint must not be bent more than 45 degrees.
    CAUTION:
    CAUTION:Do not apply excessive force to the strut and spring assembly. Do not pull the strut and spring assembly outwards by more than 28 mm.
    CAUTION:
    CAUTION:Make sure the strut and spring assembly does not move in a forwards or rearwards direction, to prevent damage to the top mount center cup.
    NOTE:
    NOTE:Make sure that the halfshaft is still fully engaged in the tripode housing.
    Detach the halfshaft from the wheel hub.
    • Pull the strut and spring assembly outwards approximately 28 mm.

  1. Remove the intermediate shaft center bearing cap.
    • Discard the bearing cap and retaining nuts.
    • Remove the intermediate shaft center bearing heat shield (if equipped).

  1. CAUTION:
    CAUTION:The inner CV joint must not be bent more than 23 degrees. The outer CV joint must not be bent more than 45 degrees.
    CAUTION:
    CAUTION:Make sure the halfshaft seal is not damaged.
    CAUTION:
    CAUTION:Plug the transaxle to prevent oil loss or dirt ingress.
    Remove the halfshaft and intermediate shaft assembly.
    • Allow the oil to drain into a suitable container (manual transaxles only).

Installation

Vehicles with automatic transaxle (CFT23)
  1. Coat the halfshaft seal with grease.
All vehicles

  1. CAUTION:
    CAUTION:The inner CV joint must not be bent more than 23 degrees. The outer CV joint must not be bent more than 45 degrees.
    CAUTION:
    CAUTION:Make sure the halfshaft seal is not damaged.
    Attach the right-hand halfshaft and intermediate shaft assembly to the transaxle.
    • Remove the special tool before fully installing the halfshaft.

  1. NOTE:
    NOTE:Install a new intermediate shaft center bearing cap and retaining nuts.
    NOTE:
    NOTE:Make sure that the intermediate shaft center bearing is correctly positioned in the intermediate shaft center bearing retaining bracket.
    Install the intermediate shaft center bearing cap.
    • Position the center bearing cap.
    • Position the intermediate shaft center bearing heat shield (if equipped).
    • Tighten the center bearing cap retaining nuts.
  1. Push the halfshaft into the tripode housing as far as the stop (approximately 20 mm).
  1. CAUTION:
    CAUTION:The inner CV joint must not be bent more than 23 degrees. The outer CV joint must not be bent more than 45 degrees.
    CAUTION:
    CAUTION:Do not apply excessive force to the strut and spring assembly. Do not pull the strut and spring assembly outwards by more than 28 mm.
    CAUTION:
    CAUTION:Make sure the strut and spring assembly does not move in a forwards or rearwards direction, to prevent damage to the top mount center cup.
    Attach the halfshaft to the wheel hub.
    • Pull the strut and spring assembly outwards approximately 28 mm.
  1. CAUTION:
    CAUTION:Make sure the strut and spring assembly does not move in a forwards or rearwards direction, to prevent damage to the top mount center cup.
    Attach the lower arm ball joint to the wheel knuckle.

  1. WARNING:
    WARNING:Install a new lower arm ball joint retaining nut. Failure to follow this instruction may result in personal injury.
    Using the special tool to prevent the ball joint from rotating, install the lower arm ball joint retaining nut.

  1. CAUTION:
    CAUTION:Install a new wheel hub retaining bolt.
    NOTE:
    NOTE:Do not tighten the wheel hub retaining bolt at this stage.
    Install the wheel hub retaining bolt.

  1. Install the crashbox.
    1. Tighten the bolt M10 x 16.
    1. Tighten the bolts M10 x 25.

  1. Attach the headlamp leveling sensor bracket to the lower arm (if equipped).
  1. Install the wheel and tire.
    For additional information, refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).

  1. Tighten the wheel hub retaining bolt (wheel and tire shown removed for clarity).
    • Tighten the wheel hub retaining bolt in two stages.
      • 1. Stage 1: 45 Nm.

        2. Stage 2: 90 degrees.

Vehicles with 4-speed automatic transaxle
  1. With the vehicle on a level surface, check the transmission fluid level.
    For additional information, refer to: Transmission Fluid Drain and Refill (307-01 Automatic Transmission/Transaxle - Vehicles With: Automatic Transmission (CFT23), General Procedures).
Vehicles with manual transaxle
  1. With the vehicle on a level surface, check the transmission fluid level and top up with clean transmission fluid until the fluid level is 5 - 10 mm below the fluid filler plug.

Mechanical Repairs > 2 Chassis > 205 Driveline > 205-04 Front Drive Halfshafts > Description and Operation > Diagnosis and Testing > Removal and Installation > Front Halfshaft RH

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