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Home >> Ford >> 1992 >> Crown Victoria Base, AOD >> Repair and Diagnosis >> Drivelines & Axles >> Differentials & Drive Axles >> Differential & Axle Shafts >> Overhaul >> Rear Axle Assembly >> Disassembly

Rear Axle Assembly: Disassembly

  1. Raise vehicle and support under rear frame crossmember. Lower hoist until axle drops down to within working range. Remove housing cover and drain lubricant.
  2. Mount a dial indicator on axle housing and measure ring gear backlash and runout. See Figure . Record readings for reassembly purposes. Ensure ring gear runout and backlash variation between teeth is within specification. See AXLE ASSEMBLY SPECIFICATIONS  table. Replace ring gear and pinion if backlash variation is excessive.
  3. Remove axle shafts. See AXLE SHAFTS & BEARINGS  . Place alignment marks on drive shaft and companion flange for reassembly reference. Remove drive shaft.
  4. Mark one bearing cap for reassembly reference. Note arrow position on bearing cap for reassembly reference. Loosen bearing cap bolts and bearing caps. Pry differential case, bearing cups and shims out until they are loose in bearing caps. Remove bearing caps and differential. Mark component location for reassembly reference.
    NOTE: Bearing cups, caps and shims must be installed in original positions.
  5. Remove the pinion nut and the companion flange. See PINION FLANGE & OIL SEAL  . Drive pinion from front bearing with soft-faced hammer. Remove pinion from rear of axle housing. Pry oil seal from axle housing.
  6. Remove front bearing. Remove pinion bearings if damaged. Mount bearing puller on pinion and press pinion from bearing. Remove, measure and record thickness of pinion shim located behind bearing.
    NOTE: DO NOT  remove pinion bearing cups unless damaged. If bearing cups are replaced, bearings must also be replaced.
  7. Bearing cups in axle housing may be removed using brass drift and hammer. Tap alternately on each side of bearing cup during removal to prevent bearing cup from binding in axle housing.
  8. If ring gear runout was beyond specification, install differential case with bearings and cups in axle housing without pinion assembly. Install a .265" (6.73 mm) shim on left side of differential case. Install left bearing cap and bolts finger tight.
  9. Apply pressure on ring gear toward left side to ensure bearing has seated in cup. Shim right side until slight drag is felt. Install bearing cap and bolts. Tighten bolts to 70-85 ft. lbs. (95-115 N.m). Rotate differential case to ensure free rotation.
  10. Install dial indicator and check ring gear runout. If runout is within specification, excessive runout was caused by improper bearing preload. If runout is still excessive, remove differential case.
  11. Mark ring gear and differential case for reassembly reference. Remove ring gear bolts. Tap ring gear from differential case. Install differential assembly in axle housing as previously described.
  12. Recheck runout on differential case flange. If the runout is within specification, install new ring gear and pinion. See AXLE ASSEMBLY SPECIFICATIONS  table. If runout is not within specification, inspect differential case or bearings for damage.
  13. If bearings are not damaged, replace differential case and bearings. Remove differential side bearings with a puller. Mark differential case and ring gear for reassembly reference. Remove pinion gears, side gears and thrust washers.
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