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HOMESERVICE MANUALSFORD2007FUSION SEL, 2.3 Z, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1190 (AUTOMATIC TRANSAXLE - 6F35)DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIESFINAL DRIVE CARRIER AND DIFFERENTIAL ASSEMBLYASSEMBLY
2007 Ford Fusion SEL, 2.3 Z, Standard

Final Drive Carrier and Differential Assembly: Assembly

2007 Ford Fusion SEL, 2.3 Z, StandardSECTION Assembly
WARNING: This page is about a different car, the 2010 Mercury Milan and 2010 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
  1. Clean and inspect the side gears and spider gears and washers for damage or excessive wear and install new components as necessary.
    Fig 1: Identifying Side Gears, Spider Gears And Washers
    G06278755Courtesy of FORD MOTOR CO.
  2. Clean and inspect the differential pin for damage or excessive wear and install new if necessary.
    Fig 2: Identifying Differential Pin
    G06278756Courtesy of FORD MOTOR CO.
  3. Clean and inspect the differential for damage and install new if necessary.
    1. Inspect the thrust bearing surfaces.
    2. Inspect the differential planetary gear teeth.
    3. Inspect the differential planetary gear teeth to be sure they spin freely and do not move back and forth or side to side excessively.
    Fig 3: Identifying Differential
    G06278757Courtesy of FORD MOTOR CO.
  4. Clean and inspect the differential sun gear for damage or excessive wear and install new if necessary.
    Fig 4: Identifying Differential Sun Gear
    G06278758Courtesy of FORD MOTOR CO.
  5. NOTE: Do not mix up the washers from the side or spider gears that they were originally assembled with. Assembly of the differential with the wrong washers can cause excessive wear to the differential carrier, spider or side gears.

    Install the washers on the side or spider gears that they were removed from.

    Fig 5: Locating Washers On Spider Gears
    G06278759Courtesy of FORD MOTOR CO.
  6. Position the side gears in the differential carrier.
    Fig 6: Positioning Side Gears In Differential Carrier
    G06278760Courtesy of FORD MOTOR CO.
  7. Place the spider gears in the differential carrier and rotate the side gears with the spider gears until the differential pin hole lines up to the holes in the spider gears.
    Fig 7: Rotating Side Gears With Spider Gears
    G06278761Courtesy of FORD MOTOR CO.
  8. Install the differential pin with the roll pin holes aligned.
    Fig 8: Locating Differential Pin And Roll Pin Hole
    G06278762Courtesy of FORD MOTOR CO.
  9. Using a suitable tool, install a new roll pin.
Fig 9: Installing Roll Pin
G06278763Courtesy 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:

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  • • 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.