2002 Mercury Villager BaseFACTORY OEM SERVICE PROCEDURE

Disassembly And Assembly Of Subassemblies: Differential: Assembly

  1. Position the side gear thrust washers on the back of the differential side gears.
    Fig 1: Positioning Side Gear Thrust Washers On Back Of Differential Side Gears
    G03412544Courtesy of FORD MOTOR CO.
  2. Position the pinion gear thrust washers on the back of the pinion gears.
    Fig 2: Positioning Pinion Gear Thrust Washers On Back Of Pinion Gears
    G03412545Courtesy of FORD MOTOR CO.
  3. Install the side gear/thrust washers into the differential case.
    Fig 3: Installing Side Gear/Thrust Washers Into Differential Case
    G03412546Courtesy of FORD MOTOR CO.
  4. Install the pinion gears in the differential case.
    • Rotate the pinion gears to properly position.
      Fig 4: Installing Pinion Gears In Differential Case
      G03412547Courtesy of FORD MOTOR CO.
  5. Install the differential pinion shaft.
    Fig 5: Installing Differential Pinion Shaft
    G03412548Courtesy of FORD MOTOR CO.
  6. Install the shaft lock pin into the differential case.
    Fig 6: Installing Shaft Lock Pin Into Differential Case
    G03412549Courtesy of FORD MOTOR CO.
  7. Install the speedometer gear.
    Fig 7: Installing Speedometer Gear
    G03412550Courtesy of FORD MOTOR CO.
  8. Install the differential bearing.
    Fig 8: Installing Differential Bearing (1 Of 2)
    G03412551Courtesy of FORD MOTOR CO.
  9. Install the differential bearing.
    Fig 9: Installing Differential Bearing (2 Of 2)
    G03412552Courtesy of FORD MOTOR CO.
    10. CAUTION: Install the final drive gear in the original position based upon the marks made during disassembly.
  10. If removed, install the differential final drive gear.
    1. Position the gear.
    2. Install the bolts.
      Fig 10: Installing Bolts
      G03412553Courtesy of FORD MOTOR CO.
Factory Service Tools

Use the Manual With the Right Hardware

Pair factory procedures with proven DIY tools so the instructions are easier to execute.

Disclosure: Verified tool recommendations may earn an affiliate commission at no cost to you.

Shop Manual-Ready ToolsCompare Repair QuoteQuote Shield Pro

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.

Rather have a pro handle this?

A certified mobile mechanic comes to your home or office. They bring the tools, you stay comfortable. No tow truck, no waiting room, no surprises.

Comes to youSame-day available12-month warranty
Get a Free Quote

No obligation. See pricing before you book.