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 SUBASSEMBLIESOUTPUT SHAFTDISASSEMBLY

2005 Ford Taurus SEL, 4D Sedan

Output Shaft: 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.

CAUTION: When pressing off components, hold the shaft so that it does not fall.

Measure the output shaft clearances.
1. Measure the clearance between 1st gear and the differential drive gear. First gear endplay is 0.05-0.33 mm (0.002-0.013 in).
2. Measure the clearance between 2nd gear and secondary 3rd gear. Second gear endplay is 0.18-0.51 mm (0.007-0.20 in).
  
  Fig 1: Identifying Clearance Between 1St Gear And Differential Drive Gear And 2Nd Gear And Secondary 3Rd Gear
  Courtesy of FORD MOTOR CO.
Using the special tools, press off the bearing and 4th gear.
- Discard the bearing.
- Always install new bearings and cups as a set. Do not install one without the other.
  
  Fig 2: Locating Special Tool, Bearing And 4Th Gear
  Courtesy of FORD MOTOR CO.
Remove and discard the snap ring.

Fig 3: Locating Snap Ring
Courtesy of FORD MOTOR CO.
Using the special tools, press off the 3rd gear and 2nd gear.

Fig 4: Locating Special Tools, 3Rd Gear And 2Nd Gear
Courtesy of FORD MOTOR CO.

CAUTION: The synchronizer blocking rings are not interchangeable. Be sure to keep them in the order that they were removed.

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.