Ford Fusion Quiz
Chassis

Rear Drive Axle Shafts. Diagnosis and Testing

In this manual: Chassis
General Information — 26Chassis — 150Powertrain — 282Electrical — 271Body and Paint — 300
3steps
~18min
2/5difficulty
Done 0 of 3

Preliminary Inspection

  1. Visually inspect the CV joints, boot, boot seals and clamps for obvious signs of mechanical damage.
  2. If an obvious cause for the observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
  3. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart: NVH.

Symptom Chart

The diagnosis in this manual assumes a certain level of skill and knowledge of Ford-approved diagnostic procedures.
REFER TO: Diagnostic Methods (100-00 General Information, Description and Operation).

Symptom Chart: NVH

Symptom Chart


Condition Possible Sources Action
Transmission clunk - loud clunk when shifting from REVERSE to DRIVE.
  • Damaged or worn constant velocity (CV) joints
  • INSPECT the constant velocity (CV) joint for wear or damage. INSTALL a new axle shaft if necessary.
    REFER TO: Rear Axle Shaft (205-05 Rear Axle Shafts, Removal and Installation).
  • Loose hub nut
  • CHECK the hub nut torque. REPLACE the hub nut if the torque does not meet specification. For the hub nuts.
    REFER TO: Wheel Bearing and Wheel Hub - All Wheel Drive (204-02 Rear Suspension, Removal and Installation).
Transmission shudder - occurs when the vehicle begins to move forward from a stop.
  • Loose hub nut
  • CHECK the hub nut torque. REPLACE the hub nut if the torque does not meet specification.
    REFER TO: Rear Axle Shaft (205-05 Rear Axle Shafts, Removal and Installation).
    REFER TO: Wheel Bearing and Wheel Hub - All Wheel Drive (204-02 Rear Suspension, Removal and Installation).
Grunt - usually associated with driveline shuck experienced during acceleration from a complete stop.
  • Constant velocity (CV) joint connection
  • CHECK the outboard constant velocity (CV) joint for proper fit in the hub. REPAIR as necessary.
    REFER TO: Rear Axle Shaft (205-05 Rear Axle Shafts, Removal and Installation).
Transmission vibration - occurs at cruising speeds.
  • Constant velocity (CV) joint binding or damage
  • CHECK the outboard CV joint for proper seating in the hub. REPAIR as necessary.
    REFER TO: Rear Axle Shaft (205-05 Rear Axle Shafts, Removal and Installation).
    REFER TO: Wheel Bearing and Wheel Hub - All Wheel Drive (204-02 Rear Suspension, Removal and Installation).

Differential Seals

NOTICE: When installing the axle shafts, do not allow the splines to contact the seals during installation, otherwise seal damage may occur.

Axle shaft seals are subject to the same types of damage as pinion seals if installed incorrectly. The seal bore must be clean and the edge free of burrs to avoid cutting or tearing the seal. The seal journal surface must be free of nicks, grooves and rough surface texture.

For differential seal information, refer to: Rear Axle Shaft Seal (205-02 Rear Drive Axle/Differential, Removal and Installation).

Test yourself

A quick Ford Fusion quiz: every answer comes with an explanation and a link to the manual page.