2003 Ford ZX2 AutomaticFACTORY OEM SERVICE PROCEDURE

Disassembly And Assembly Of Subassemblies: Differential: Assembly

  1. Clean the components with a suitable solvent and use compressed air to dry all parts. Perform the following before assembly:
    • Check for damaged or worn gears and washers.
    • Inspect the speedometer drive gear for damage or wear.
  2. Install the speedometer drive gear.
    Fig 1: Installing Speedometer Drive Gear
    G01372089Courtesy of FORD MOTOR CO.
  3. Use (A) Driver Handle or a press, along with (B) Bearing Cone Replacer to install a new (C) differential bearing (speedometer drive gear end).
    Fig 2: Installing Differential Bearing (Speedometer Drive Gear End)
    G01372090Courtesy of FORD MOTOR CO.
  4. Use (A) Driver Handle or a press, along with (B) Bearing Cone Replacer to install a new (C) differential bearing (ring gear end).
    Fig 3: Installing Differential Bearing (Ring Gear End)
    G01372091Courtesy of FORD MOTOR CO.
  5. Install the differential side gear thrust washers, differential pinion thrust washers, differential pinion gears, and the differential side gears.
    • Rotate the gears to align the differential gears with the pinion shaft hole.
    Fig 4: Aligning Differential Gears With Pinion Shaft Hole
    G01372092Courtesy of FORD MOTOR CO.
  6. Install the differential pinion shaft.
    Fig 5: Installing Differential Pinion Shaft
    G01372093Courtesy of FORD MOTOR CO.
  7. Install the differential pinion shaft lock pin. Stake the differential pinion shaft lock pin to prevent it from coming out of the differential case.
    Fig 6: Installing Differential Pinion Shaft Lock Pin
    G01372094Courtesy of FORD MOTOR CO.
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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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