FORD FIESTA 2007 Workshop Manual

205-04-9 Front Drive Halfshafts 205-04-9
REMOVAL AND INSTALLATION
6. Install the wheel and tire.
' For additional information, refer to: Wheel - and Tire (204-04 Wheels and Tires, Removal
and Installation).
7m CAUTION:^^^ a socket to tighten the
wheel hub retaining nut to prevent damage.
Tighten the wheel hub retaining nut.
8. Tighten the strut and spring assembly top
mount retaining nuts.
Vehicles with manual transaxle
9. With the vehicle on a level surface, fill the
transaxle with transmission fluid until the oil
level is just below the bottom of the filler
hole.
Vehicles with automatic transaxle
10. Check the transmission fluid level and top
up with clean automatic transmission oil.
For additional information, refer to:
Transmission Fluid Drain and Refill I (307-01 Automatic
Transmission/Transaxle - Vehicles With:
4-Speed Automatic Transmission
(AW81-40), General Procedures).
- - -- -
2006.0 Fiesta 1212006 GII 31 04en
procarmanuals.com

205-04-1 0 Front Drive Halfshafts 205-04-1 0
REMOVAL AND INSTALLATION
Front Halfshaft RH(14 321 0)
('
Special Tool(s) 3. Remove the wheel and tire. (.
I I Installer, Halfshaft For additional information, refer to: Wheel
and Tire
(204-04 Wheels and Tires, Removal
and Installation).
4m A~AU~l0N:~rotect the ball joint seal using
a soft cloth to prevent damage.
I I I Detach the lower arm ball joint from the I wheel knuckle.
General Equipment
Remove the heat shield.
Four leg puller
Removal
I. Loosen the strut and spring assembly top
mount retaining nuts by three turns.
5m ACAUTION:S~~~~~~ the halfshaft. The inner
joint must not be bent more than
18 degrees.
The outer joint must not be bent more than
45 degrees.
Using a suitable four leg puller, detach the
halfshaft from the wheel hub.
" ~CAUTION:US~ a socket to loosen the Secure the halfshaft to one side. wheel hub retaining nut to prevent damage.
Remove the wheel hub retaining nut.
Discard the wheel hub retaining nut.
6m ACAUTION:S~~~~~~ the halfshaft. The inner .
joint must not be bent more than 18 degrees. (
The outer joint must not be bent more than
45 degrees.
2006.0 Fiesta IZIZOO~ ~1131 05en
procarmanuals.com

205-04-1 1 Front Drive Halfshafts 205-04-1 1
REMOVAL AND INSTALLATION
N0TE:Do not damage the inner constant velocity 1. Slide a small screwdriver under the boot seat
(CV) joint boot. to allow the air to escape.
N0TE:Discard the grease.
Remove the halfshaft.
Remove and discard the constant velocity
(CV) joint boot clamp.
Installation
Im &AUTION:T~~ total amount of grease
must not exceed
100 grams.
i Apply grease to the intermediate shaft.
*' &AUTION:S~~~~~~ the halfshaft. The inner
joint must not be bent more than
18 degrees.
The outer joint must not be bent more than
45 degrees.
Attach the halfshaft to the intermediate shaft.
3. N0TE:Do not damage the inner constant
velocity (CV) joint boot.
N0TE:Make sure that the intermediate shaft mating
surface for the joint boot is clean.
2. Insert the constant velocity (CV) joint in as
far as it will go, then pull it back
approximately
20 mm.
4. N0TE:lnstall a new CV joint boot clamp.
Using a suitable grip wrench, install the inner
CV joint boot clamp.
5m ~CAUTION:M~~~ sure the halfshaft is
completely installed into the wheel hub.
Using the special tool, install the halfshaft.
Install the inner constant velocity (CV) joint
boot (halfshaft shown removed for clarity).
6. N0TE:lnstall a new wheel hub retaining nut.
2006.0 Fiesta 1212006 GI 131 05en
procarmanuals.com

205-04-1 2 Front Drive Halfshafts 205-04-1 2
REMOVAL AND INSTALLATION
N0TE:Do not fully tighten the wheel hub retaining 9. Install the wheel and tire.
nut at this stage. For additional information, refer to: Wheel
Install the wheel hub retaining nut. and
Tire (204-04 Wheels and Tires, Removal
and Installation).
lorn &AUTION:U~~ a socket to tighten the
wheel hub retaining nut to prevent damage.
7m &AUTION:M~~~ sure that the heat shield
is installed to prevent damage to the ball
joint.
Install the heat shield.
*' &AUTION:T~~ lower arm pinch bolt must
be installed from the rear of the wheel
knuckle.
Attach the lower arm ball joint to the wheel
knuckle. Tighten
the wheel hub retaining nut.
11. Tighten the strut and spring assembly top
mount retaining nuts.
2006.0 Fiesta 1212006 GII 3105en
procarmanuals.com

205-04-1 3 Front Drive Halfshafts 205-04-1 3
REMOVAL AND INSTALLATION
Intermediate Shaft
I
Materials
Name Specification
Removal
Manual transmission
1 fluid
A WARN1NG:Refer to the Material Safety Data
Sheets for the Automatic Transmission
Fluid E-AW. Failure to follow this
instruction may result in personal injury.
Certain Transmission and Power Steering
fluids supplied to Ford contain additives
which may cause skin irritation or other
skin reactions after contact.
WSD-M2C200-C
For additional information, refer to: Health
and Safety Precautions
(1 00-00 General
Information, Description and Operation).
See
- Transmission Fluids.
I. Remove the right-hand halfshaft.
, For additional information, refer to: Front
i, Halfshaft RH (205-04 Front Drive Halfshafts,
Removal and Installation).
2. Remove the intermediate shaft center
bearing cap.
1. Remove and discard the locknuts.
2. Detach the heatshield from the bearing cap.
3. Remove and discard the center bearing cap.
3m ACAUTION:D~ not damage the halfshaft
oil seal.
N0TE:Plug the transaxle to prevent oil loss or dirt
ingress.
For additional information, refer to: Health and
Safety Precautions
(1 00-00 General Information,
Description and Operation).
See
- Transmission Fluids.
Remove the intermediate shaft.
Allow the oil to drain into a suitable container.
For additional information, refer to: Health
and Safety Precautions
(I 00-00 General
Information, Description and Operation).
See
- Transmission Fluids.
Slide the heatshield off the intermediate
shaft.
Installation
All vehicles
I' ACAUTION:D~ not damage the halfshaft
oil seal.
Install the intermediate shaft.
Slide the heatshield onto the intermediate
shaft.
2006.0 Fiesta 1212006 GI 52541 en
procarmanuals.com

205-04-1 4 Front Drive Halfshafts 205-04-1 4
REMOVAL AND INSTALLATION
2. N0TE:lnstall a new intermediate shaft center
bearing cap and locknuts.
Install the intermediate shaft center bearing
cap.
I. Install the center bearing cap.
2. Attach the heatshield to the bearing cap.
3. Install the locknuts.
3. Install the right-hand halfshaft.
For additional information, refer to: Front
Halfshaft RH (205-04 Front Drive Halfshafts,
Removal and Installation).
Vehicles with manual transaxle
4. With the vehicle on the level surface, fill the
transaxle with transmission fluid until the oil
level is just below the bottom of the filler
hole.
Vehicles with automatic transaxle
5. Check the transmission fluid level and top
up with clean automatic transmission oil.
For additional information, refer to:
Transmission Fluid Drain and Refill
(307-01
Automatic Transmission/Transaxle -
Vehicles With: 4-Speed Automatic
Transmission
(AW81-40), General
Procedures).
2006.0 Fiesta 1212006 GI 52541 en
procarmanuals.com

205-04-1 5 Front Drive Halfshafts 205-04-1 5
REMOVAL AND INSTALLATION
Inner Constant Velocity (CV) Joint Boot(l4 336 0)
Special Tool(s)
I I Clamping Tool, Boot I
Remover, BearingIGear
205-3 1 0 (1 5-09 1
A~se vise jaw protectors for all operations
in a vise.
N0TE:Secure the halfshaft in a vise.
Detach the inner CV joint housing from the
halfshaft.
1. Remove and discard the CV joint boot
retaining clamps.
2. Remove the CV joint housing and discard
the grease.
I I Installer, Extension Housing I
BushingIOil Seal
308-046 (1 6-0 1 6)
Materials
Name Specification
1 Grease I WSS-M 1 C259A1 I
4. Remove and discard the spider circlip.
Removal 5. Using the special tool, remove the spider.
I. Remove the right-hand halfshaft.
For additional information, refer to Halfshaft
RH in this section.
2. Remove the left-hand halfshaft.
For additional information, refer to Halfshaft
LH in this section.
3. CAUTIONS:
ADO not bent the inner constant velocity
(CV) joint more than
18 degrees and the outer
CV joint more than
45 degrees.
2006.0 Fiesta 1212006 GI 52548en
procarmanuals.com

205-04-1 6 Front Drive Halfshafts 205-04-1 6
REMOVAL AND INSTALLATION
6. Remove the inner CV joint boot. 3. N0TE:lnstall the spider with the chamfer
Mark the halfshaft were the CV joint boot is facing towards the halfshaft.
located. Using the special tool, install the spider. (
installation 4. N0TE:lnstall a new spider circlip.
I. N0TE:Make sure that the inner constant Install the spider circlip.
velocity (CV) joint boot is installed to the
marks on the halfshaft.
Install the inner CV joint boot.
'' ACAUTION:T~~ total amount of grease in
the inner CV joint must not exceed
85 grams.
Apply grease to the inner CV joint boot.
2. N0TE:lnstall a new CV joint boot retaining I I
clamp.
Using the special tool, install the CV joint
boot retaining clamp.
6. Attach the inner CV joint housing to the
halfshaft (left hand side shown for clarity).
2006.0 Fiesta iu200s GI 52548en
procarmanuals.com

205-04-1 7 Front Drive Halfshafts 205-04-1 7
REMOVAL AND INSTALLATION
1. Use a suitable screwdriver under the CV joint
boot to allow air to escape.
2. Install the CV joint boot housing and pull it
backwards
20 mm.
7. N0TE:lnstall a new CV joint boot retaining
clamp.
N0TE:Make sure that the CV joint boot is clamped
at the measured
postion.
Using a special tool, install the CV joint boot
retaining clamp.
8. Install the right-hand halfshaft.
For additional information, refer to Halfshaft
RH in this section.
9. Install the left-hand halfshaft.
For additional information, refer to Halfshaft
LH in this section.
2006.0 Fiesta 1212006 GI 52548en
procarmanuals.com

205-04-1 8 Front Drive Halfshafts 205-04-1 8
REMOVAL AND INSTALLATION
Outer Constant Velocity (CV) Joint Boot(l4 338 0)
Special Tool(~)
I
-
I Clamping Tool, Boot
Retaining Clamp
204-1 69 (1 4-044)
14044
Materials
Name Specification
1 Grease I WSS-MI ~259-v
Remove and discard the grease. I
Removal Installation
&AUTION:The outer constant velocity I' ~CAUTION:T~~ total amount of grease in
(CV) joint is a press fit. Do not disassemble. the
inner constant velocity (CV) joint must
Failure to follow this instruction may result not
exceed
85 grams.
in damage to the outer CV joint.
Apply grease to the outer CV joint boot.
Remove the inner CV joint boot.
For additional information, refer to Inner
Constant Velocity (CV) Joint Boot in this
section.
2. CAUTIONS:
ADO not bent the inner CV joint more than
18 degrees and the outer CV joint more than
45 degrees.
n~se vise jaw protectors for all operations
in a vise.
N0TE:Secure the halfshaft in a vise.
N0TE:Mark the halfshaft were the CV joint boot is *. Install the Outer CV joint boot=
located.
Use a suitable screwdriver under the boot to
Remove the outer CV joint boot. allow air to escape.
Remove and discard the CV joint boot
retaining clamps.
2006.0 Fiesta 1212006 GI 52549en
procarmanuals.com