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Differential Assembly: Disassembly

NOTE: Pinion drive selective oil slinger affects pinion depth adjustment. If oil slinger is damaged during disassembly procedure, measure slinger thickness and replace with oil slinger of equal thickness.
  1. With axle housing removed from vehicle, remove housing cover and drain differential fluid. Mount axle housing in Holding Fixture (T57L-500-B) using Adapters (T90T-4000-A) and Spacer (T80T-4000-B2).
  2. Rotate shafts until open side of "C" clip on inner end of axle shaft can be reached. Remove "C" clips. Remove axle shafts. Remove both left and right axle housing oil seals and needle bearings using slide hammer, Collet (D80L-100-A) and Actuator Pin (D80L-100-H).
  3. Note matched numbers or letters on differential bearing caps and carrier for reassembly reference. Remove bearing caps. Install Housing Spreader (T90T-4000-A). See Fig 1 . Mount dial indicator on axle housing to measure amount of spread.
    CAUTION: DO NOT spread carrier housing more than .015" (.38 mm); permanent damage to housing could result.
  4. Spread axle housing to a maximum of .015" (.38 mm). Remove dial indicator. Carefully pry differential assembly out of housing. Remove spreader immediately so housing does not permanently distort.
  5. Remove and tag side bearing races to indicate from which side of carrier they were removed. Turn nose of axle housing up. Mark pinion companion flange-to-drive pinion position for installation reference.
  6. Using Companion Flange Holder (T78P-4851-A), hold companion flange while removing drive pinion nut and washer. Remove companion flange. If flange shows wear in sealing area, replace flange. Remove drive pinion by tapping with soft-faced mallet.
  7. Remove and discard drive pinion oil seal. Remove outer pinion bearing, oil slinger and collapsible spacer. Drive out inner drive pinion bearing race using Pinion Bearing Race Remover (T86T-4628-BH) and Driver Handle (T80T-4000-W).
    8. NOTE: Oil baffles DO NOT have selective thicknesses. If oil baffle is damaged during bearing race removal, replace oil baffle.
  8. Remove oil baffle from inner bearing bore. Turn nose of housing carrier down. Using pinion bearing race remover and driver handle, remove outer pinion bearing race.
  9. Place Universal Bearing Remover (D81L-4220-A) in vise to secure tool while removing differential side bearings. Use Step Plate (D80L-630-3) under bearing to protect bearing from puller. Keep bearings, bearing races and shims in sets, marked according to location on carrier.
  10. Place differential case in vise with rags underneath to protect ring gear. Remove and discard ring gear bolts. Tap ring gear with soft-faced mallet to remove ring gear from case. Using drift and hammer, drive out pinion shaft lock pin. Remove pinion shaft.
  11. Rotate side gears until pinion gears are aligned with case opening. Remove pinion gears and thrust washers. Remove side gears with thrust washers. Using universal bearing remover, remove inner pinion bearing and oil slinger from drive pinion.
Fig 1: Spreading Axle Housing
G95I27506Courtesy of FORD MOTOR CO.
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