Ford Focus Service Manual: Differentials - Final Drive Carrier and Differential Assembly

	Handle 205-153 (T80T-4000-W)
	Installer, Differential Bearing 205-206 (T83T-4221-A)
	Puller, Bearing 205-D064 (D84L-1123-A) or equivalent
	Remover/Installer, Front Wheel Hub 204-069 (T81P-1104-C)
	Step Plate 205-D015 (T80L-630-4) or equivalent

Disassembly

1. NOTICE: Do not damage the speed sensor wheel.

   Using the Front Wheel Hub Remover/Installer, Bearing Puller and Step Plate, remove the differential case bearings.

1. NOTE:

   The roll pin cannot be driven through the housing.

   NOTE:

   Note the location of the indent left by the flag on the roll pin.

   Remove the differential pinion shaft.
   1. Remove and discard the roll pin.
   1. Remove the pinion shaft.

1. Remove the differential side gears.
   1. Rotate the differential pinion gears 90 degrees and remove the differential pinion gears with the thrust washers.
   1. Remove the differential side gears with the thrust washers.

1. Clean all parts thoroughly in clean solvent and blow dry with moisture-free, regulated compressed air.

1. Inspect the differential parts of damage and wear.
   • Pinion gear teeth and bores
   • Side gear teeth and 5 splines
   • Thrust washers
   • Differential pinion shaft
   • Differential case bearing and surfaces

Assembly

1. Lubricate the gears and thrust washers with clean transmission fluid.

1. Install the different pinion gears and thrust washers.
   1. Install the differential side gears and thrust washers.
   1. Install the differential pinion gears and thrust washers by rotating 90 degrees.

1. NOTE:

   Install a new roll pin.

   Install the differential pinion shaft.

   1. Install the pinion shaft.
   1. Install the roll pin.

1. NOTE:

   LH shown, RH similar.

   Using the Differential Bearing Installer and Handle, install the differential case bearings.