Guide to Replace Drive Axle on a 94 Ford Escort

The 1994 Ford Escort base model came with a 1.9-liter four-cylinder engine and a five-speed manual transmission. Your Escort's constant velocity shafts transfer rotation from the transmission differential side gears to the front wheel hubs. The CV joints allow power to be transmitted to the front wheels uninterrupted when turning or going over bumps. The CV shaft is serviced as an assembly; if either CV joint begins to fail you have to replace the entire shaft. Replacing your CV shaft is an in-depth job, but is well within the realm of the home mechanic.

Instructions

Removal

1

Park the vehicle on a level surface and set the parking brake. Loosen the lug nuts on the wheel to be serviced with a lug wrench. Lift the front of the vehicle into the air with a floor jack and place jack stands under the front sub-frame rails. Lower the vehicle until it rests securely on the jack stands.

2

Remove the lug nuts from the wheel. Remove the wheel and tire from the vehicle and set it aside. Pry up the center pin for all of the splash guard retainers. Remove the splash guard retainers and splash guard and set them aside.

3

Place a small pointed chisel into the staked portion of the axle and axle nut. Tap the chisel with a hammer to unlock the axle nut. Instruct a helper to sit in the vehicle and apply the brakes. Remove the axle shaft nut with a 32 mm socket and breaker bar. Instruct the helper to exit the vehicle.

4

Straiten the legs of the outer tie-rod end cotter pin and remove the cotter pin with pliers. Remove the tie-rod end castle nut with a socket and ratchet. Separate the tie-rod end from the steering knuckle with the tie-rod separator.

5

Remove the lower ball joint pinch nut with a socket and ratchet while holding the pinch nut with a wrench. Place a pry bar between the lower control arm and the steering knuckle and pry down on the control arm to separate the ball joint from the control arm. Skip to step 7, if you are replacing the driver side axle shaft.

6

Pull outward on the steering knuckle and brake assembly and pull the passenger side axle shaft out of the wheel hub. Place a pry bar between the passenger side axle and the transmission case; Pry outward on the axle shaft to disengage the axle circlip from the differential side gears. Pull the passenger side axle shaft straight out of the transmission, exercising caution not to drag the axle splines across the axle seal. Install a transmission plug into the axle shaft hole on the transmission.

7

Pull outward on the steering knuckle and brake assembly. Pull the axle shaft out of the wheel hub by hand and position the steering knuckle aside. Place a small block of wood on the floor jack arm and lift the jack arm until the wood contacts the transmission case. Lift the transmission a quarter inch and remove the four nuts securing the transmission mount to the cross-member with a socket and ratchet.

8

Place a jack stand under the rear portion of the cross-member and remove the rear cross-member bolts. Support the front portion of the cross-member by hand and remove the two front mounting bolts. Lower the cross-member and set it aside. Place a pry bar between the transmission case and the driver side axle and pry outward to release the axle circlip from the differential side gears. Support the axle shaft and pull it straight out of the transmission. Install a transmission into the axle shaft hole in the transmission.

Installation

9

Proceed to step 3 if you are replacing the passenger side axle. Inspect the new driver side axle shaft and ensure a new circlip is installed on the transmission end of the axle. Apply a small amount of wheel bearing grease to the splines of the new axle. Remove the transmission plug from the axle hole. Inspect the oil seal for any wear or damage and replace as necessary. Lift the new driver side axle into position and slide it into the transmission. Push the axle shaft into place so that the circlip clicks into the differential side gears. Pull on the inboard axle shaft tripod, if the shaft is properly installed it will not remove by hand.

10

Lift the cross-member into place and install the rear mounting nuts and the front mounting bolts. Tighten the front cross-member bolts to 27 to 40 foot-pounds with a torque wrench. Tighten the rear mounting nuts to 55 to 69 foot-pounds. Install the four transmission mount to cross-member nuts and tighten with a socket and ratchet.

11

Apply a small amount of wheel bearing grease to the axle shaft splines and slide the passenger side axle into the transmission. Push the axle shaft until the circlip clips into the groove of the differential side gears. Pull on the axle shaft inboard tripod, if the axle is properly installed the shaft will not remove by hand.

12

Pull outward on the steering knuckle and brake assembly and guide the axle shaft into the wheel hub. Pry down on the lower control arm and guide the lower ball joint stud into the steering knuckle. Apply Loctite 290 compound to the ball joint pinch bolt and guide it thought the steering knuckle. Install the pinch nut and tighten it to between 32 and 43 foot-pounds while hold the pinch bolt with a wrench.

13

Set the outer tie-rod end into the steering knuckle and install the castle nut. Tighten the castle nut to 20 foot-pounds. Tighten the castle nut slightly to line up the castle nut groves with the ball joint stud hole, if necessary. Install a new cotter pin and bend the legs in opposite directions around the castle nut with pliers.

14

Install a new axle shaft nut onto the end of the axle shaft and tighten it hand tight. Instruct a helper to sit in the vehicle and apply the brakes. Tighten the new axle shaft nut to between 174 and 235 foot-pounds with a 32 mm socket and a torque wrench. Instruct the helper to exit the vehicle. Place the wheel and tire onto the vehicle and install the lug nuts hand tight.

15

Lift the front of the vehicle off the jack stands and remove the jack stands from under the vehicle. Lower the vehicle to the ground. Tighten the lug nuts to 82 foot-pounds in a criss-cross pattern. Drive the vehicle to a local repair shop to have the front-end alignment checked and adjusted as necessary.