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HOMESERVICE MANUALSFORD2004ECONOLINE E150, VAN CARGO, 4.6 WREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 309 (AUTOMATIC TRANSMISSION)DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIESFINAL DRIVEDISASSEMBLY
2004 Ford Econoline E150, Van Cargo, 4.6 W

Final Drive: Disassembly

2004 Ford Econoline E150, Van Cargo, 4.6 WSECTION Disassembly
WARNING: This page is about a different car, the 2004 Mercury Monterey and 2004 Ford Freestar. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the No. 16 final drive gear front thrust bearing.
    Fig 1: Removing No. 16 Final Drive Gear Front Thrust Bearing
    G03244969Courtesy of FORD MOTOR CO.
  2. Remove the park gear.
    Fig 2: Removing Park Gear
    G03244970Courtesy of FORD MOTOR CO.
  3. Remove the final drive sun gear and deflector.
    Fig 3: Removing Final Drive Sun Gear And Deflector
    G03244971Courtesy of FORD MOTOR CO.
  4. Remove the differential pinion shaft roll pin.
    Fig 4: Removing Differential Pinion Shaft Roll Pin
    G03244972Courtesy of FORD MOTOR CO.
  5. Remove the differential pinion shaft.
    Fig 5: Removing Differential Pinion Shaft
    G03244973Courtesy of FORD MOTOR CO.
  6. Rotate the output shaft and remove the differential pinion gear, and the differential pinion thrust washers.
    Fig 6: Removing Differential Pinion Gear, And Differential Pinion Thrust Washers
    G03244974Courtesy of FORD MOTOR CO.
  7. Remove the differential side gear and differential side gear thrust washer.
    Fig 7: Removing Differential Side Gear And Differential Side Gear Thrust Washer
    G03244975Courtesy of FORD MOTOR CO.
  8. Remove the differential side gear and differential side gear thrust washer.
    1. Move the output shaft.
    2. Use the snap ring pliers to remove the retaining ring.
    3. Remove the output shaft.
    4. Remove the differential side gear and differential side gear thrust washer.
    Fig 8: Removing Differential Side Gear And Differential Side Gear Thrust Washer
    G03244976Courtesy of FORD MOTOR CO.
RENDER: 1.0x

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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.