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.
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HOMESERVICE MANUALSFORD2005FIVE HUNDRED 2WD V6-3.0L VIN 1REPAIR AND DIAGNOSISTRANSMISSION AND DRIVETRAINCONTINUOUSLY VARIABLE TRANSMISSION/TRANSAXLEDIFFERENTIALDIFFERENTIAL TRANSFER SHAFTSERVICE AND REPAIR
2005 Ford Five Hundred 2WD V6-3.0L VIN 1
Differential Transfer Shaft: Service and Repair
2005 Ford Five Hundred 2WD V6-3.0L VIN 1SECTION Service and Repair
Side Shaft Gear Assembly-Front Wheel Drive (FWD)
Special Tool(s)
Material
Removal
CAUTION: MERCON, MERCON V, MERCON SP, Motorcraft Premium Automatic Transmission Fluid and Motorcraft Continuously Variable Chain Type Transmission Fluid are not interchangeable transmission fluids. The use of any fluid other than what is recommended for this transmission will cause transmission damage.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the Exhaust Gas Recirculation (EGR) tube.
3. Remove the side shaft gear assembly dust cover.
4. Remove the 4 bolts and remove the side shaft gear assembly.
5. Remove and discard the side shaft gear assembly O-ring seal.
Installation
1. Install a new side shaft gear assembly O-ring seal.
2. Install the side shaft gear assembly bolts.
^ Tighten to 23 Nm (17 ft. lbs.).
3. Using the special tool, install the side shaft gear assembly dust cover.
4. Install the EGR tube.
^ Tighten to 40 Nm (30 ft. lbs.).
5. Fill the transaxle with clean CVT automatic transmission fluid. Use the transmission fluid level setting procedure to fill the transaxle.
Special Tool(s)
Material
Removal
CAUTION: MERCON, MERCON V, MERCON SP, Motorcraft Premium Automatic Transmission Fluid and Motorcraft Continuously Variable Chain Type Transmission Fluid are not interchangeable transmission fluids. The use of any fluid other than what is recommended for this transmission will cause transmission damage.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the Exhaust Gas Recirculation (EGR) tube.
3. Remove the side shaft gear assembly dust cover.
4. Remove the 4 bolts and remove the side shaft gear assembly.
5. Remove and discard the side shaft gear assembly O-ring seal.
Installation
1. Install a new side shaft gear assembly O-ring seal.
2. Install the side shaft gear assembly bolts.
^ Tighten to 23 Nm (17 ft. lbs.).
3. Using the special tool, install the side shaft gear assembly dust cover.
4. Install the EGR tube.
^ Tighten to 40 Nm (30 ft. lbs.).
5. Fill the transaxle with clean CVT automatic transmission fluid. Use the transmission fluid level setting procedure to fill the transaxle.
RENDER: 1.0x
NO RELATED
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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.