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HOMESERVICE MANUALSFORD2007FUSION SEL, 2.3 Z, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1034 (MANUAL TRANSMISSION)DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIESDIFFERENTIAL - 4WDDISASSEMBLY
2007 Ford Fusion SEL, 2.3 Z, Standard

Differential - 4WD: Disassembly

2007 Ford Fusion SEL, 2.3 Z, StandardSECTION Disassembly
WARNING: This page is about a different car, the 2008 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: Backlash specification: 0.02-0.08 mm (0.0008-0.0031 in).
  1. Using the special tool, measure and record the backlash for the differential side gears. Install a new differential if beyond specification.
    2. Fig 1: Checking Backlash Of Differential Side Gears
    GF0025402Courtesy of FORD MOTOR CO.
  2. Remove the 10 reduction gear bolts.
  3. Remove the reduction gear.
  4. Remove the 10 final drive gear bolts.
  5. Remove the final drive gear.
  6. Using the special tools, remove the differential side bearing.
    • Discard the differential side bearing.
    7. Fig 2: Removing Differential Side Bearing
    GF0025403Courtesy of FORD MOTOR CO.
  7. Remove the spacer.
  8. Remove the vehicle speed sensor (VSS) drive gear.
  9. Using the special tools, remove the differential side bearing.
    • Discard the differential side bearing.
    10. Fig 3: Removing Differential Side Bearing
    GF0025403Courtesy of FORD MOTOR CO.
RENDER: 1.0x

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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.