2005 Ford Freestar BaseFACTORY OEM SERVICE PROCEDURE

Final Drive: Assembly

NOTE: If excessive wobble or rotational binding or damage is found, a new final drive planet and carrier will need to be installed.
  1. Inspect the differential pinion and side gears for looseness, discoloration, cracks or excessive gear wear.
    1. Inspect the final drive planet gears.
    2. Inspect the pinion shaft bores.
    Fig 1: Inspecting Differential Pinion And Side Gears For Looseness, Discoloration, Cracks Or Excessive Gear Wear
    G03957262Courtesy of FORD MOTOR CO.
  2. Install the differential side gear and differential side gear thrust washer.
    1. Install the differential side gear and differential side gear thrust washer.
    2. Install the output shaft.
    3. Install the retaining ring.
    Fig 2: Installing Differential Side Gear And Differential Side Gear Thrust Washer
    G03957263Courtesy of FORD MOTOR CO.
  3. Install the differential side gear and differential side gear thrust washer.
    Fig 3: Installing Differential Side Gear And Differential Side Gear Thrust Washer
    G03957260Courtesy of FORD MOTOR CO.
  4. Install the differential pinion gears, and differential pinion thrust washers.
    Fig 4: Installing Differential Pinion Gears, And Differential Pinion Thrust Washers
    G03957265Courtesy of FORD MOTOR CO.
  5. Install the differential pinion shaft.
    Fig 5: Installing Differential Pinion Shaft
    G03957266Courtesy of FORD MOTOR CO.
  6. Install the differential pinion shaft roll pin.
    Fig 6: Installing Differential Pinion Shaft Roll Pin
    G03957267Courtesy of FORD MOTOR CO.
  7. Install the final drive sun gear and deflector assembly.
    Fig 7: Installing Final Drive Sun Gear And Deflector Assembly
    G03957256Courtesy of FORD MOTOR CO.
  8. Install the park gear.
    Fig 8: Installing Park Gear
    G03957255Courtesy of FORD MOTOR CO.
  9. Install the No. 16 final drive gear front thrust bearing.
    Fig 9: Installing No. 16 Final Drive Gear Front Thrust Bearing
    G03957254Courtesy of FORD MOTOR CO.
  10. Install new retaining circle clips.
    Fig 10: Installing New Retaining Circle Clips
    G03957271Courtesy of FORD MOTOR CO.
  11. Install the low intermediate clutch piston and rear planet support.
    Fig 11: Installing Low Intermediate Clutch Piston And Rear Planet Support
    G03957272Courtesy of FORD MOTOR CO.
Factory Service Tools

Use the Manual With the Right Hardware

Pair factory procedures with proven DIY tools so the instructions are easier to execute.

Disclosure: Verified tool recommendations may earn an affiliate commission at no cost to you.

Shop Manual-Ready ToolsCompare Repair QuoteQuote Shield Pro

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.

Rather have a pro handle this?

A certified mobile mechanic comes to your home or office. They bring the tools, you stay comfortable. No tow truck, no waiting room, no surprises.

Comes to youSame-day available12-month warranty
Get a Free Quote

No obligation. See pricing before you book.