2006 Ford Freestar BaseFACTORY OEM SERVICE PROCEDURE

Final Drive: Disassembly

  1. Remove the No. 16 final drive gear front thrust bearing.
    Fig 1: Identifying Final Drive Gear Front Thrust Bearing
    G04661525Courtesy of FORD MOTOR CO.
  2. Remove the park gear.
    Fig 2: Locating Park Gear
    G04661526Courtesy of FORD MOTOR CO.
  3. Remove the final drive sun gear and deflector.
    Fig 3: Locating Final Drive Sun Gear And Deflector
    G04661527Courtesy of FORD MOTOR CO.
  4. Remove the differential pinion shaft roll pin.
    Fig 4: Locating Differential Pinion Shaft Roll Pin
    G04661528Courtesy of FORD MOTOR CO.
  5. Remove the differential pinion shaft.
    Fig 5: Locating Differential Pinion Shaft
    G04661529Courtesy of FORD MOTOR CO.
  6. Rotate the output shaft and remove the differential pinion gear, and the differential pinion thrust washers.
    Fig 6: Rotating Output Shaft and Removing Differential Pinion Gear, And Differential Pinion Thrust Washers
    G04661530Courtesy of FORD MOTOR CO.
  7. Remove the differential side gear and differential side gear thrust washer.
    Fig 7: Locating Differential Side Gear Thrust Washer
    G04661531Courtesy 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
      G04661532Courtesy 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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