Side Shaft Gear Assembly: Disassembly

WARNING: This page is about a different car, the 2006 Mercury Montego, 2006 Ford Freestyle, and 2006 Ford Five Hundred. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Note the side gear assembly is model-dependent, depending on gear ratio.

If there is excessive contamination present, this entire procedure will need to be carried out.

Inspect the side shaft gear assembly for damage. If no damage is indicated the installation of a new O-ring seal and dust cover only will be required.

Inspect the side shaft gear assembly for damage (chipped teeth, worn bearing or contamination). If no damage or contamination is indicated the installation of a new O-ring seal and dust cover will only be required.
Remove and discard the side gear assembly O-ring seal.

Fig 1: Locating Side Gear Assembly O-Ring Seal
Courtesy of FORD MOTOR CO.
Remove and discard the rubber dust cover.

Fig 2: Locating Rubber Dust Cover
Courtesy of FORD MOTOR CO.

NOTE: It may be necessary to press the gear assembly into the cover to remove the snap ring.

Fig 3: Locating Snap Ring

Courtesy of FORD MOTOR CO.

If required, remove and discard the snap ring.
If required, using the special tool, press the gear from the bearing.

Fig 4: Identifying Special Tool (205-D064)
Courtesy of FORD MOTOR CO.
The cover, bearing and retaining snap ring are only serviced as an assembly.

Fig 5: Locating Snap Ring
Courtesy of FORD MOTOR CO.