Differential Case: Removal

WARNING: This page is about a different car, the 2006 Ford Pickup and 2006 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

With the vehicle in NEUTRAL, position it on a hoist For additional information, refer to JACKING & LIFTING .
Remove the 10 bolts and the differential housing cover.
- Drain the lubricant from the rear axle.
Clean the gasket material from the differential housing cover and the differential housing.
Remove the axle shafts. For additional information, refer to WHEEL HUBS AND BEARINGS - FULL FLOATING AXLE - DANA .

NOTE: Note the positions of the mating letters stamped vertically and horizontally on the bearing caps and the differential housing before removing the bearing caps.

Fig 1: Locating Bearing Caps

Courtesy of FORD MOTOR CO.

Remove the 4 bolts and the 2 bearing caps.

CAUTION: Do not spread the differential housing more than specified.

Fig 2: Using Special Tool To Spread Differential Housing

Courtesy of FORD MOTOR CO.

Using the special tools, spread the differential housing.

CAUTION: It will be necessary to use large pry bars to remove the differential assembly from the differential housing. Do not damage the differential ring gear when carrying out this step.

NOTE: Mark or tag the differential bearing cups, indicating from which side they were removed.

Remove the differential assembly with the bearing cups.
- Inspect the differential bearing cups for deep scores, galling and spalling.
  
  Fig 3: Locating Differential Assembly
  Courtesy of FORD MOTOR CO.

NOTE: Mark or tag the outboard spacers indicating from which side they were removed.

Remove the 2 outboard spacers.
- Inspect the spacers for nicks, bending or grooved conditions.
  
  Fig 4: Identifying Outboard Spacers
  Courtesy of FORD MOTOR CO.

NOTE: Differential bearings shims are available in thicknesses of 0.762, 0.787, 0.813, 0.838, 0.864, 0.889 and 0.914 mm (0.030, 0.031, 0.032, 0.033, 0.034, 0.035 and 0.036 in).

NOTE: If damaged, install new differential bearing shims.

NOTE: Install new differential bearings and cups if removing the bearings from the differential case.

Using the special tools, remove the differential bearings.
- Tag the selective inboard spacers to identify the side from which they were removed.
  
  Fig 5: Removing Differential Bearings Using Special Tools
  Courtesy of FORD MOTOR CO.

NOTE: Use a vise with brass jaws or wood blocks.

Place the differential case in a vise.

CAUTION: Do not damage the anti-lock speed sensor ring when removing the differential ring gear.

NOTE: Always use new bolts upon reassembly.

Fig 6: Identifying Ring Gear

Courtesy of FORD MOTOR CO.

Remove and discard 8 of the ring gear bolts. Leave 4 bolts loosely assembled, 90 degrees apart.
Tap each remaining bolt head alternately with a rawhide or plastic hammer to loosen the differential ring gear. Remove and discard the 4 bolts. Remove the differential ring gear.

Fig 7: Tapping Loosley Installed Bolts To Remove Ring Gear
Courtesy of FORD MOTOR CO.
If necessary, remove and discard the anti-lock speed sensor ring with a soft-faced hammer.

Fig 8: Removing Anti-Lock Speed Sensor Ring
Courtesy of FORD MOTOR CO.