MITCHELL 1 ARTICLE - AXLE SHAFTS - FRONT 1988-93 Drive Axles - FWD Axle Shafts Page 1 of 3

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AXLE SHAFTS - FRONT

1988-93 Drive Axles - FWD Axle Shafts

DESCRIPTION & OPERATION

Axle shafts transfer power from transaxle to driving wheels. All axle shafts consist of a shaft with a flexible Constant Velocity (CV) joint at
each end. Inner CV joint is coupled to transaxle by splines. Outer CV joint is splined to hub assembly and secured by axle shaft nut.

Three different types of axle shaft CV joints are used: Double Offset Joint (DOJ) or Rzeppa type, Birfield Joint (BJ) and the Tripot Joint (TJ).

CV joint boots protect CV joints by maintaining proper lubrication and preventing contaminants from entering joint. Boots must be replaced
when signs of leakage or cracks are present. Inner CV joint may be disassembled and serviced. Outer CV joint boot may be replaced, but outer
Birfield CV joint must NOT be disassembled. It must be replaced as an assembly, if faulty.

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To prevent torsional vibration and torque steer on turbocharged Capri vehicles, an intermediate shaft and conventional axle shaft are used on
the right side. Both shafts are of similar length and are supported by a bearing, which is attached to engine.

CV JOINT IDENTIFICATION
Application Joint Type
Outer Joint Birfield (BJ)
Inner Joint
Automatic Transaxle Tripot (TJ)
Manual Transaxle Rzeppa (DOJ)

TROUBLE SHOOTING

NOTE: See TROUBLE SHOOTING - BASIC PROCEDURES article in GENERAL INFORMATION.

REMOVAL, DISASSEMBLY, REASSEMBLY & INSTALLATION

FWD AXLE SHAFTS

Removal

1. Raise and support vehicle. Remove lower underbody splash shields. Drain transaxle fluid. Remove front wheels and loosen axle shaft
lock nut. On Capri, remove stabilizer bar-to-control arm attaching nuts, bolt, washers and bushings. On Festiva, remove stabilizer bar
attaching nuts and bracket. On all models, remove joint clamp bolt from lower control arm. Pry downward and separate steering knuckle
from ball joint, taking care not to damage ball joint dust boot.
2. On Capri turbo, remove bolts securing intermediate shaft bearing bracket to engine. On all models, slowly pry axle shaft from transaxle
using a flat-tip screwdriver or pry bar. Axle is held into transaxle by a circlip fitted to the end of the axle. Remove axle shaft from wheel
hub. If difficult to remove, use axle puller to remove axle from drive hub. Remove axle shaft from transaxle. Plug transaxle openings
with Plugs (T87C-7025-C ). Remove axle shaft assembly from vehicle. See Fig. 1 .

CAUTION: Damage to CV joint will occur if a hammer is used to separate half-shaft from wheel hub.

Fig. 1: Removing & Installing Axle Shafts

Courtesy of FORD MOTOR CO.

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MITCHELL 1 ARTICLE - AXLE SHAFTS - FRONT 1988-93 Drive Axles - FWD Axle Shafts Page 2 of 3

Fig. 2: Exploded View Of Axle Shafts & CV Joints

Courtesy of FORD MOTOR CO.

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Fig. 3: Measuring & Identifying Axle Shafts & CV Boots
Courtesy of FORD MOTOR CO.

Disassembly (Rzeppa/DOJ Type)

1. Label and remove CV joint boot. Mark alignment of axle shaft to outer race of CV joint. Remove circlip and outer bearing race housing.
Mark alignment of inner race to shaft. Remove inner snap ring. Remove cage assembly. See Fig. 2 .
2. Pry ball bearings from bearing cage. Mark alignment of bearing cage to inner race. Rotate inner race about 30 degrees and remove from
cage assembly. If necessary, remove remaining boot.

NOTE: Check old grease for contamination by rubbing between two fingers. Any gritty feeling indicates
contaminated CV joint. If joint is contaminated disassemble, clean, and inspect thoroughly.

Reassembly (Rzeppa/DOJ Type)

1. Apply Grease (E43Z-19590-A ) to all areas of CV joint during reassembly. Reverse disassembly procedure for reassembly, noting
alignment marks made during disassembly. Ensure chamfer on bearing cage faces snap ring. Lubricate outer race housing with 1.4-2.1
ounces (40-60 g) of grease.
2. Install right side dynamic damper at a distance of 18.99-19.27" (482.5-489.5 mm) from outboard end of axle shaft. Installed length of
CV boot should be 3.5" (90 mm). See Fig. 3 .

Disassembly (Tripot Type)

Remove boot clamp and boot. Paint an alignment mark of axle shaft to outer race of CV joint. Remove circlip and outer bearing race housing.
Mark alignment of inner race to shaft. Remove snap ring and remove tripot assembly using a soft brass drift and hammer. See Fig. 2 .

Reassembly (Tripot Type)

Apply Grease (E43Z-19590-A ) to all areas of CV joint during reassembly. Reverse removal procedure, noting alignment marks made during
disassembly. Ensure chamfer on bearing cage faces snap ring. Lubricate outer race housing with 3.5 ounces (100 g) of grease. Installed length
of CV boot should be 3.5" (90 mm).

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MITCHELL 1 ARTICLE - AXLE SHAFTS - FRONT 1988-93 Drive Axles - FWD Axle Shafts Page 3 of 3

NOTE: Always install NEW cotter pin, washer and suspension lock nuts.

Installation (All)

1. To install axle shaft, reverse removal procedure. Always install a NEW retaining circlip. Check seals at both ends of axle shaft. If
necessary, replace seals prior to installation. Lubricate transaxle seal lip with transaxle oil. See Fig. 1 .
2. After installing axle shaft into transaxle, pull axle shaft outward by hand to ensure proper engagement of retaining circlip and snap ring.
Install axle shaft into wheel hub. Align suspension alignment marks and tighten nuts.

INTERMEDIATE SHAFT

Removal

Intermediate shaft and axle shaft are removed as an assembly. See FWD AXLE SHAFTS under REMOVAL, DISASSEMBLY,
REASSEMBLY & INSTALLATION.

Disassembly

Separate intermediate shaft from axle shaft. Remove circlip from intermediate shaft and press off bearing and bracket assembly. See Fig. 4 .
Press bearing out of bracket. Inspect bracket for damage or wear and replace if necessary.

Reassembly

Press NEW bearing into bracket and install NEW seals. Install bearing and bracket assembly onto intermediate shaft. Install NEW circlip.
Assemble intermediate shaft to axle shaft.

Installation

Intermediate shaft and axle shaft are installed as an assembly. See FWD AXLE SHAFTS under REMOVAL, DISASSEMBLY,
REASSEMBLY & INSTALLATION.

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Fig. 4: Exploded View Of Intermediate Shaft
Courtesy of FORD MOTOR CO.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Axle Nut (1) 116-173 (157-235)
Ball Joint Pinch Bolt 32-40 (43-54)
Steering Knuckle-To-Strut Bolt 69-86 (93-117)
Caliper Retaining Bolt 29-36 (39-49)
Stabilizer Bar Bracket Nut 40-50 (54-68)
Stabilizer Link Bolt 9-13 (12-18)
Tie Rod End Nut 21-32 (29-44)
Wheel Lug Nuts 66-89 (90-120)
(1) Ensure locking flange on nut is staked into axle slot.

Copyright 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.

Article GUID: A00042994

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