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Disassembly And Assembly: Axle: Disassembly

WARNING: This page is about a different car, the 2005 Mercury Mountaineer and 2005 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING .
  2. Remove the axle assembly. For additional information, refer to AXLE ASSEMBLY .
  3. Measure and record the pinion bearing preload.
    • Using a Nm torque wrench, rotate the pinion. Measure the torque required to maintain pinion rotation.
      Fig 1: Measuring Pinion Bearing Preload
      G03944374Courtesy of FORD MOTOR CO.
  4. Remove the differential housing cover bolts and the differential housing cover.
  5. Remove the RH axle shaft.
    Fig 2: Removing RH Axle Shaft
    G03912816Courtesy of FORD MOTOR CO.
  6. Using the special tool, remove the axle seal.
    Fig 3: Removing Axle Seal
    G03944612Courtesy of FORD MOTOR CO.
  7. Using the special tool, remove the axle shaft bearing.
    Fig 4: Removing Axle Shaft Bearing
    G03944613Courtesy of FORD MOTOR CO.
  8. Remove the differential bearing caps.
    1. Remove the differential bearing cap bolts.
    2. Remove and identify the differential bearing caps.
      Fig 5: Removing Differential Bearing Caps
      G03913068Courtesy of FORD MOTOR CO.
  9. Install the special tool.
    Fig 6: Installing Special Tool
    G03944429Courtesy of FORD MOTOR CO.
  10. Install the axle assembly into the bench fixture.
    Fig 7: Installing Axle Assembly Into Bench Fixture
    G03944427Courtesy of FORD MOTOR CO.
  11. Install the special tools.
    Fig 8: Installing Special Housing Spreader Tools
    G03912953Courtesy of FORD MOTOR CO.
    12. CAUTION: Overspreading can damage the differential housing.
  12. Spread the differential housing to the specification.
    1. Adjust the special tool to zero.
    2. Tighten the differential carrier spreader screw.
    3. Remove the dial indicator.
      Fig 9: Spreading Differential Housing To Specification
      G03912954Courtesy of FORD MOTOR CO.
    13. CAUTION: Use wood blocks to avoid damaging the differential housing.
  13. Remove the differential assembly from the housing.
    1. Position the wood blocks.
    2. Push downward on the pry bars.
    3. Remove the differential assembly.
    4. Remove the special tool.
      Fig 10: Removing Differential Assembly From Differential Housing
      G03912955Courtesy of FORD MOTOR CO.
  14. Remove the differential ring gear.
    1. Remove and discard the differential ring gear bolts.
    2. Using a drift that will bottom out in the differential ring gear bolt holes, separate the differential ring gear from the differential assembly.
      Fig 11: Removing Differential Ring Gear
      G03913131Courtesy of FORD MOTOR CO.
  15. Assemble the special tools.
    Fig 12: Assembling Special Tools
    G03912957Courtesy of FORD MOTOR CO.
  16. Position the special tool on the differential bearing.
    Fig 13: Positioning Special Tool On Differential Bearing
    G03912883Courtesy of FORD MOTOR CO.
  17. Using the special tool, remove the differential bearings.
    Fig 14: Removing Differential Bearings
    G03912959Courtesy of FORD MOTOR CO.
  18. If necessary, disassemble the differential assembly. For additional information, refer to DIFFERENTIAL CASE .
  19. Index-mark the pinion flange and the pinion gear stem.
    Fig 15: Identifying Index-Mark On Pinion Flange And Pinion Gear Stem
    G03944375Courtesy of FORD MOTOR CO.
  20. Using the special tool to hold the pinion flange, remove and discard the pinion nut and washer.
    Fig 16: Removing Pinion Nut
    G03944625Courtesy of FORD MOTOR CO.
  21. Using the special tool, remove the pinion flange.
    Fig 17: Removing Pinion Flange
    G03912962Courtesy of FORD MOTOR CO.
  22. Using the special tool, remove the drive pinion oil seal.
    Fig 18: Removing Drive Pinion Oil Seal
    G03944382Courtesy of FORD MOTOR CO.
  23. Inspect the pinion flange for burrs and damage. Inspect the end of the pinion flange that contacts the outer pinion bearing cone, the pinion nut counterbore and the drive pinion oil seal surface for nicks. Discard the pinion flange if damaged.
  24. Press the inner pinion bearing off the pinion.
    1. Install special tool under the inner pinion bearing.
    2. Using a shop press, remove the inner pinion bearing from the pinion gear stem.
      Fig 19: Removing Inner Pinion Bearing From Pinion Gear Stem
      G03912968Courtesy of FORD MOTOR CO.
  25. Measure and record the thickness of the drive pinion position shim for reference during assembly.
    Fig 20: Identifying Drive Pinion & Shim
    G03944522Courtesy of FORD MOTOR CO.
    26. NOTE: To prevent it from becoming misaligned in the bore, remove the inner pinion bearing cup by tapping alternately on each side of the inner pinion bearing cup with a brass drift.
    Fig 21: Identifying Inner Pinion Bearing Cup
    G03912967Courtesy of FORD MOTOR CO.
  26. If necessary, remove the inner pinion bearing cup.
    27. NOTE: To prevent it from becoming misaligned in the bore, remove the outer pinion bearing cup by tapping alternately on each side of the outer pinion bearing cup with a brass drift.
    Fig 22: Removing Outer Pinion Bearing Cup
    G03944443Courtesy of FORD MOTOR CO.
  27. If necessary, remove the outer pinion bearing cup.
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