Differential Case: Removal

WARNING: This page is about a different car, the 2002 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.

Remove the axle shafts. Refer to AXLE SHAFT .
Wipe the lubricant from the internal working parts and visually inspect the parts for wear or damage.
Rotate the differential case to see if there is any roughness which would indicate damaged bearings or gears.

Fig 1: Rotating Differential Case
Courtesy of FORD MOTOR CO.

NOTE: There is a space between the anti-lock speed sensor ring and the ring gear for measuring ring gear backface runout.

Fig 2: Checking Ring Gear Backface Runout

Courtesy of FORD MOTOR CO.

Position the special tool and inspect ring gear backface runout.

CAUTION: Mark the position of the bearing caps, as arrows may not be visible. The bearing caps must be installed in their identical locations and positions.

Loosen the differential case.
1. Remove the four bearing cap bolts.
2. Remove the two bearing caps.
  
  Fig 3: Loosening Differential Case
  Courtesy of FORD MOTOR CO.

WARNING: Be careful not to allow the differential case to fall.

CAUTION: Place a wood block between the pry bar and the rear axle housing (4010) to protect the machined surface from damage.

Fig 4: Removing Differential Case From Rear Axle Housing

Courtesy of FORD MOTOR CO.

Using pry bars and wood blocks, remove the differential case from the rear axle housing.
Remove the 10 ring gear bolts.

Fig 5: Removing Ring Gear Bolts
Courtesy of FORD MOTOR CO.

CAUTION: Care should be taken not to damage the ring bolt hole threads.

NOTE: The anti-lock speed sensor ring cannot be reused once removed.

Fig 6: Removing Ring Gear

Courtesy of FORD MOTOR CO.

Insert a punch in the bolt holes and drive off the ring gear and, if necessary, the anti-lock speed sensor ring.
Install the differential case.
- Position the differential case assembly, including the bearing cups and shims, in the rear axle housing. Install the differential bearing caps and the differential bearing cap bolts.
  
  Fig 7: Identifying Tightening Torque Of Differential Case Bolts
  Courtesy of FORD MOTOR CO.
Position the special tool.
1. Rotate the differential case to ensure the differential bearings are correctly seated.
2. Install the special tool.
  
  Fig 8: Positioning Special Tool
  Courtesy of FORD MOTOR CO.
Rotate the differential case and measure the differential case runout without the ring gear.
- If runout is less than specification, install a new ring gear and pinion. If runout exceeds specification, the ring gear is true and the concern is due to either a damaged differential case or differential bearings. Inspect the differential bearings. If the differential bearings are not damaged, replace both the differential case and the differential bearings.
  
  Fig 9: Measuring Differential Case Runout Without Ring Gear
  Courtesy of FORD MOTOR CO.
Remove the differential case from the rear axle housing and remove the differential bearings using the special tools.

Fig 10: Removing Differential Bearings
Courtesy of FORD MOTOR CO.
Using the special tool install the new differential bearings on the differential case.

Fig 11: Installing Differential Bearings On Differential Case
Courtesy of FORD MOTOR CO.
Install the differential case. Position the differential case assembly, including the bearing cups and shims in the rear axle housing. Tighten bearing caps to specifications.

Fig 12: Identifying Tightening Torque Of Differential Case Bolts
Courtesy of FORD MOTOR CO.
Measure the differential case runout without the ring gear, and check the case runout again with the new differential bearings.
- If the runout is now less than the specification shown, use the new differential bearings for assembly.
- If the runout is still excessive, the differential case is damaged and must be replaced.
  
  Fig 13: Measuring Differential Case Runout
  Courtesy of FORD MOTOR CO.