Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
2003 Ford ZX2 AutomaticFACTORY OEM SERVICE PROCEDURE
Output Gear: Assembly
- Clean the components with a suitable solvent and use compressed air to dry all parts. Perform the following before assembly:
- Inspect the output gear for damaged or excessively worn teeth.
- Inspect the output gear splines for damage or wear.
- Use (A) Dust Boot Replacer, (B) Bearing Cone Replacer, and (C) Axle Bearing/Seal Plate to press the (D) output gear bearings onto the output gear.
- Apply Motorcraft MERCON® Multi-Purpose Automatic Transmission Fluid XT-2-QDX or equivalent meeting Ford specification MERCON to the new seal rings and install them on the output gear.
- Seal ring inner diameter: 27.6 mm (1.087 in).
Factory Service Tools
Use the Manual With the Right Hardware
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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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