Lincoln Nautilus: Rear Drive Axle/Differential / Axle Assembly. Removal and Installation

Special Tool(s) / General Equipment

	205-242 Remover, Fuel Injector TKIT-1986-LM TKIT-1986-F
	205-243 Remover, Halfshaft TKIT-1986-LM TKIT-1986-F
Transmission Jack
Wooden Block

Removal

NOTE: Removal steps in this procedure may contain installation details.

1. Remove the fuel tank.
   Refer to: Fuel Tank (310-01A Fuel Tank and Lines - 2.0L EcoBoost (184kW/250PS) – MI4, Removal and Installation).
   

1. Remove the wheel bearing and wheel hub.
   Refer to: Wheel Bearing and Wheel Hub - AWD (204-02 Rear Suspension, Removal and Installation).
   

1. On both sides.
   
   • Using the special tools, disconnect the halfshafts from differential and position it aside.
     Use Special Service Tool: 205-242  Remover, Fuel Injector. , 205-243  Remover, Halfshaft.
   • Support the halfshaft.
     

1. 1. Remove and discard the halfshaft retaining circlip.
      
   2. Inspect the halfshaft end for damage.
      

1. Remove the muffler and tail pipe.
   Refer to: Muffler and Tailpipe (309-00A Exhaust System - 2.0L EcoBoost (184kW/250PS) – MI4, Removal and Installation).
   Refer to: Muffler and Tailpipe (309-00B Exhaust System - 2.7L EcoBoost (238kW/324PS), Removal and Installation).
   

1. 
   Separate the driveshaft from the drive pinion flange.
   

   1. NOTE: Make sure that the component aligns with the installation mark.

      Index-mark the driveshaft flange and the RDU companion flange to maintain alignment during installation.
      
   2. Remove and discard the driveshaft to drive pinion companion flange bolts and the retaining straps.
      Torque: 26 lb.ft (35 Nm)

   3. NOTICE: Do not remove driveshaft from the pinion flange by pulling on the driveshaft tube. Damage to the CV-joint can result.

      Using a general equipment, separate the driveshaft from the drive pinion flange.
      
   4. Position and support the driveshaft aside.
      

1. Disconnect the RDU actuator motor electrical connector and detach wiring harness retainer.
   

1. Disconnect the speed sensor electrical connector and detach wiring harness retainers.
   

1. 1. Remove the rear differential vent hose from RDU .
      
   2. Detach the connector and position the vent hose aside.
      

1. NOTE: Re-attach the ground cable after servicing the RDU.

   1. Remove the ground cable nut.
      Torque: 106 lb.in (12 Nm)
   2. Turn the ground cable.
      
   3. Remove the ground cable.
      

1. Position a transmission jack and wooden block to secure the RDU .
   Use the General Equipment: Transmission Jack
   Use the General Equipment: Wooden Block

1. Remove the front RDU mounting bolts and nuts.
   Use the General Equipment: Transmission Jack
   Use the General Equipment: Wooden Block
   Torque: 66 lb.ft (90 Nm)

1. Remove the rear RDU mounting bolts.
   Torque: 66 lb.ft (90 Nm)

1. 1. Lower the transmission jack.
      
   2. Remove the rear axle arm protection shield and spacer.
      
   3. Remove the rear axle assembly.
      

Installation

1. To install, reverse the removal procedure.
   

1. Check the differential fluid level.
   Refer to: Differential Fluid Level Check (205-02 Rear Drive Axle/Differential, General Procedures).
   

1. NOTICE: If replacing the axle assembly, the AWD control module will need to be reconfigured with the new RDU bar code information. If the new bar code information does not match the existing AWD control module information, driveline damage or driveability concerns can occur.

   NOTE: Using the diagnostic scan tool, carry out the rear drive unit calibration routine.

   NOTE: The 16/17 -digit alpha numeric bar code is located on the label attached to the RDU . Using the scan tool, configure RDU bar code to AWD module through the OBD port.