2003 Ford Windstar BaseFACTORY OEM SERVICE PROCEDURE

Final Drive: Assembly

NOTE: If excessive wobble or rotational binding or damage is found a new final drive planet and carrier will need to be installed.
  1. Inspect the differential pinion and side gears for looseness, discoloration, cracks or excessive gear wear.
    1. Inspect the final drive planet gears.
    2. Inspect the pinion shaft bores.
      Fig 1: Inspecting Differential Pinion And Side Gears
      G01308957Courtesy of FORD MOTOR CO.
  2. Install the differential side gear and differential side gear thrust washer.
    1. Install the differential side gear and differential side gear thrust washer.
    2. Install the output shaft.
    3. Install the retaining ring.
      Fig 2: Installing Differential Side Gear And Differential Side Gear Thrust Washer
      G01308958Courtesy of FORD MOTOR CO.
  3. Install the differential side gear and differential side gear thrust washer.
    Fig 3: Installing Differential Side Gear And Differential Side Gear Thrust Washer
    G01308959Courtesy of FORD MOTOR CO.
  4. Install the differential pinion gears, and differential pinion thrust washers.
    Fig 4: Installing Differential Pinion Gears, And Differential Pinion Thrust Washers
    G01308960Courtesy of FORD MOTOR CO.
  5. Install the differential pinion shaft.
    Fig 5: Installing Differential Pinion Shaft
    G01308961Courtesy of FORD MOTOR CO.
  6. Install the differential pinion shaft roll pin.
    Fig 6: Installing Differential Pinion Shaft Roll Pin
    G01308962Courtesy of FORD MOTOR CO.
  7. Install the final drive sun gear and deflector assembly.
    Fig 7: Installing Final Drive Sun Gear And Deflector Assembly
    G01308963Courtesy of FORD MOTOR CO.
  8. Install the park gear.
    Fig 8: Installing Park Gear
    G01308964Courtesy of FORD MOTOR CO.
  9. Install the No. 16 final drive gear front thrust bearing.
    Fig 9: Installing Final Drive Gear Front Thrust Bearing
    G01308965Courtesy of FORD MOTOR CO.
  10. Install new retaining circle clips.
    Fig 10: Installing Retaining Circle Clips
    G01308966Courtesy of FORD MOTOR CO.
  11. Install the low intermediate clutch piston and rear planet support.
    Fig 11: Installing Low Intermediate Clutch Piston And Rear Planet Support
    G01308967Courtesy of FORD MOTOR CO.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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