2004 Ford Freestar BaseFACTORY OEM SERVICE PROCEDURE

Final Drive: Disassembly

  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.
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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