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Differential Assembly: Disassembly

WARNING: This page is about a different car, the 2002 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: Extreme care must be taken not to damage aluminum axle housing while carrying out these procedures.
  1. Using Transmission Holding Fixture (307-003, T57L-500-B), mount axle housing to a bench. See Fig 1 .
  2. Using Torque Converter Fluid Seal Remover (307-309, T94P-77001-BH) and Slide Hammer (100-001, T50T-100-A), remove axle shaft seals. See Figure .
  3. Using Transfer Case Bearing Cup Remover (308-125, T87P-7120-D) and Slide Hammer (100-001, T50T-100-A), remove stub shaft bearings. See Figure .
    4. CAUTION: Overspreading differential can damage axle housing. Maximum spread is .010" (.25 mm).
  4. Remove side carrier bearing cap bolts. Using Differential Housing Spreader (205-001, TOOL-4000-E) and Adapter (205-001-1), spread axle housing. See Fig 2 . Remove differential carrier from the case and mark bearing cups for installation reference.
    5. CAUTION: Ensure drive pinion does not fall out of axle case when drive pinion nut is removed.
    NOTE: Drive pinion nut is staked in groove of drive pinion shaft. There may be metal left in groove that must be removed.
  5. Remove differential housing spreader and adapter. Using the Drive Pinion Nut Holding Tool (205-503) and Drive Pinion Nut Socket (205-175), remove the drive pinion nut. See Fig 3 . Remove drive pinion, collapsible spacer and inner drive pinion bearing. Remove outer drive pinion bearing. Discard collapsible spacer.
    6. CAUTION: DO NOT damage axle housing when removing inner drive pinion bearing cup.
  6. Using Drive Pinion Outer Bearing Remover (205-249) and Adapter Handle (205-153), remove outer drive pinion bearing cup. See Fig 4 . Using Drive Pinion Inner Bearing Cup Remover (205-248, T86T-4628-AH) and adapter handle, remove the inner drive pinion bearing cup and oil baffle. See Fig 5 . Discard oil baffle.
  7. Using Drive Pinion and Differential/Carrier Puller (205-D036, D81L-4220-A) and Step Plate Adapter (205-D016), remove differential case bearing and shims. See Fig 6 . Mark bearing cups and cones together to indicate which side of the carrier they were removed from. Discard any damaged shims.
    8. WARNING: Gear teeth have sharp edges. Use care when handling drive pinion. Failure to follow these instructions may result in personal injury.
    NOTE: Make sure to note the location of the pinion gears, side gears and thrust washers to assemble in the same locations.
  8. Remove and discard ring gear bolts. Remove differential pinion shaft lock pin and differential pinion shaft. See Fig 7 . Rotate the pinion gears and pinion gear thrust washers to the window in differential carrier and remove.
  9. Remove the 2 pinion gears (1), 2 side gears (2) and 4 thrust washers. See Fig 8 . Using drive pinion and differential/carrier puller and step plate adapter, remove drive pinion bearing and drive pinion position shim. See Fig 9 .
Fig 1: View Of Holding Fixture
G00186919Courtesy of FORD MOTOR CO.
Fig 2: Removing & Installing Differential Carrier
G00186920Courtesy of FORD MOTOR CO.
Fig 3: Removing & Installing Drive Pinion Nut
G00186921Courtesy of FORD MOTOR CO.
Fig 4: Removing Drive Pinion Outer Bearing
G00186922Courtesy of FORD MOTOR CO.
Fig 5: Removing Inner Drive Pinion Bearing Cup
G00186923Courtesy of FORD MOTOR CO.
Fig 6: Removing Carrier Bearings & Shims
G00186924Courtesy of FORD MOTOR CO.
Fig 7: Removing & Installing Differential Shaft Lock Pin
G00186925Courtesy of FORD MOTOR CO.
Fig 8: Removing & Installing Pinion & Side Gears
G00186926Courtesy of FORD MOTOR CO.
Fig 9: Removing Drive Pinion Bearing & Shim
G00186927Courtesy of FORD MOTOR CO.
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