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 MANUALSFORD2005TAURUS SEL, 4D SEDANREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 621 (MANUAL TRANSAXLE/TRANSMISSION)DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIESDIFFERENTIALDISASSEMBLY

2005 Ford Taurus SEL, 4D Sedan

Disassembly And Assembly Of Subassemblies: Differential: Disassembly

2005 Ford Taurus SEL, 4D SedanSECTION Disassembly

WARNING: This page is about a different car, the 2006 Mercury Milan and 2006 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

Inspect the differential for wear or damage.
- Inspect for damaged or worn gears.
- Inspect for worn or damaged differential bearings.
- Install new components as necessary.
Remove the differential side gears and thrust washers.
- Rotate the differential side gears to remove.
  
  Fig 1: Locating Differential Side Gears
  Courtesy of FORD MOTOR CO.
Using the special tools, remove the differential bearing.
- Always install new bearings and cups as a set. Do not install one without the other.
  
  Fig 2: Locating Special Tools And Differential Bearing
  Courtesy of FORD MOTOR CO.
Remove the speedometer drive gear.

Fig 3: Locating Special Tools And Speedometer Drive Gear
Courtesy of FORD MOTOR CO.
Rotate the differential assembly with the speedometer drive gear side facing downward. Remove the other differential bearing.
- Always install new bearings and cups as a set. Do not install one without the other.
  
  Fig 4: Locating Special Tools And Differential Bearing
  Courtesy of FORD MOTOR CO.
Remove and discard the differential pinion shaft lock pin.

Fig 5: Locating Differential Pinion Shaft Lock Pin
Courtesy of FORD MOTOR CO.
Remove the differential pinion shaft, the differential pinon gears and the thrust washers.

RENDER: 1.0x

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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.