Differential Ring And Pinion: Removal

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.

Remove the axle assembly. For additional information, refer to AXLE ASSEMBLY .
Drain the front axle assembly.
1. Remove the differential housing cover bolts.
2. Remove the differential cover.
  
  Fig 1: Identifying Differential Housing Cover
  Courtesy of FORD MOTOR CO.
Install the special tools on the differential housing.

Fig 2: Installing Special Tools On Differential Housing
Courtesy of FORD MOTOR CO.
Install the special tool fixture on the adapters and mount on a bench.

Fig 3: Installing Special Tool Fixture On Adapters And Mount On Bench
Courtesy of FORD MOTOR CO.
Remove the differential bearing caps.
1. Remove the differential bearing cap bolts.
2. Remove and identify the differential bearing caps.
  
  Fig 4: Removing Differential Bearing Caps - With ID Marks
  Courtesy of FORD MOTOR CO.
Install the special tool.

Fig 5: Installing Special Tool On Differential
Courtesy of FORD MOTOR CO.
Install the special tools.

Fig 6: Installing Special Housing Spreader Tools
Courtesy of FORD MOTOR CO.

CAUTION: Overspreading can damage the differential housing.

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 7: Spreading Differential Housing To Specification
  Courtesy of FORD MOTOR CO.

CAUTION: Use wood blocks to avoid damaging the differential housing.

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 8: Removing Differential Assembly From Differential Housing
  Courtesy of FORD MOTOR CO.
Remove the differential ring gear bolts and the differential ring gear.
- Use a drift punch to separate the differential ring gear from the differential case.
  
  Fig 9: Removing Differential Ring Gear Bolts And Differential Ring Gear
  Courtesy of FORD MOTOR CO.
Assemble the special tools.

Fig 10: Assembling Special Tools
Courtesy of FORD MOTOR CO.
Position the special tool on the differential bearing.

Fig 11: Positioning Special Tool On Differential Bearing
Courtesy of FORD MOTOR CO.
Using the special tool, remove the differential bearings.

Fig 12: Removing Differential Bearings
Courtesy of FORD MOTOR CO.
Using the special tool to hold the pinion flange, remove and discard the pinion nut and washer.

Fig 13: Identifying Pinion Flange Holding Tool
Courtesy of FORD MOTOR CO.
Using the special tool, remove the pinion flange.

Fig 14: Removing Pinion Flange
Courtesy of FORD MOTOR CO.

WARNING: The gear teeth have sharp edges. Handle the gear with care to avoid personal injury.

Using a soft-face hammer, remove the pinion from the differential housing.
1. Hold the pinion inside the differential housing.
2. Use a soft-face hammer to remove the pinion from the outer pinion bearing.
  
  Fig 15: Removing Pinion From Outer Pinion Bearing
  Courtesy of FORD MOTOR CO.
Using the special tool, remove the drive pinion oil seal.

Fig 16: Removing Drive Pinion Oil Seal
Courtesy of FORD MOTOR CO.
Remove the front axle drive pinion shaft oil slinger and the outer pinion bearing.

Fig 17: Identifying Outer Drive Pinion Bearing And Drive Pinion Shaft Oil Slinger
Courtesy of FORD MOTOR CO.

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 18: Identifying Inner Pinion Bearing Cup

Courtesy of FORD MOTOR CO.

Remove the inner pinion bearing cup.

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 19: Removing Outer Pinion Bearing Cup

Courtesy of FORD MOTOR CO.

Remove the outer pinion bearing cup.