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Home >> Ford >> 2000 >> Contour SE, 2.0 3, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 385 (Front Drive Axle/Differential - DANA 35) >> Removal & Installation >> Differential Bearings >> Removal

Differential Bearings: Removal

WARNING: This page is about a different car, the 2002 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: Many components and surfaces in the axle are precision machined. Careful handling during disassembly, cleaning, inspection, and assembly will prevent unnecessary damage to machined surfaces.
  1. Remove the front drive axle assembly from the vehicle. For additional information, refer to AXLE ASSEMBLY - FRONT  .
    • Remove the front axle dampener from the axle to frame bracket, if so equipped.
  2. Attach the axle assembly to the special tool.
    Fig 1: Attaching Axle Assembly To Special Tool
    G03434777Courtesy of FORD MOTOR CO.
    3. NOTE: Place a suitable drain pan under the axle.
    Fig 2: Removing Differential Housing Cover
    G03434778Courtesy of FORD MOTOR CO.
  3. Remove the differential housing cover.
    1. Remove the bolts.
    2. Remove the differential housing cover.
  4. Drain the axle lubricant from the differential housing.
  5. Remove the axle shaft using a jerking motion.
    Fig 3: Removing Axle Shaft
    G03434779Courtesy of FORD MOTOR CO.
    6. CAUTION: The matched numbers or letters stamped on both of the differential bearing caps and the differential housing must correspond during assembly.
    Fig 4: Removing Differential Bearing Caps
    G03434780Courtesy of FORD MOTOR CO.
  6. Remove the differential bearing caps.
    1. Remove the bolts.
    2. Remove the differential bearing caps.
    7. CAUTION: The Housing Spreader Adapter bolts have a minimum thread engagement as specified.
    Fig 5: Installing Special Tool
    G03434781Courtesy of FORD MOTOR CO.
  7. Install the special tool.
  8. Install the special tools.
    • Position the Clutch Housing Alignment Adapter needle in the Housing Spreader Adapter hole.
    Fig 6: Installing Special Tool
    G03434782Courtesy of FORD MOTOR CO.
    9. CAUTION: Over spreading can damage the differential housing.
    Fig 7: Spreading Differential Housing To Specification
    G03434783Courtesy of FORD MOTOR CO.
  9. Spread the differential housing to the specification.
    1. Adjust the special tool to zero.
    2. Tighten the Differential Carrier Spreader screw to spread the differential housing to the specification.
    3. Remove the Dial Indicator with Bracketry and the Clutch Housing Alignment Adapter.
    10. CAUTION: Use wood blocks to avoid damaging the differential housing.
    Fig 8: Removing Differential Assembly From Differential Housing
    G03434784Courtesy of FORD MOTOR CO.
  10. Remove the differential assembly from the differential housing.
    1. Position the wood blocks.
    2. Push downward on the pry bars.
    3. Remove the differential assembly.
    4. Remove the special tool.
  11. 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
    G03434785Courtesy of FORD MOTOR CO.
  12. Assemble the special tools.
    Fig 10: Assembling Special Tools
    G03434786Courtesy of FORD MOTOR CO.
  13. Position the special tool on the differential bearing.
    Fig 11: Positioning Special Tool On Differential Bearing
    G03434787Courtesy of FORD MOTOR CO.
  14. Using the special tool, remove the differential bearings.
    Fig 12: Removing Differential Bearings
    G03434788Courtesy of FORD MOTOR CO.
  15. Index-mark the pinion flange and the pinion stem.
    Fig 13: Index-Marking Pinion Flange & Pinion Stem
    G03434789Courtesy of FORD MOTOR CO.
  16. Use the special tool to hold the flange while removing the nut.
    Fig 14: Using Special Tool To Hold Flange While Removing Nut
    G03434790Courtesy of FORD MOTOR CO.
  17. Using the special tool, remove the pinion flange.
    Fig 15: Using Special Tool, Removing Pinion Flange
    G03434791Courtesy of FORD MOTOR CO.
    18. WARNING: The gear teeth have sharp edges. Handle the gear with care to avoid personal injury.
    CAUTION: Never use a metal hammer on the pinion. Use a soft mallet to drive the pinion out of the differential housing.
    Fig 16: Removing Pinion From Differential Housing
    G03434792Courtesy of FORD MOTOR CO.
  18. 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 differential housing.
  19. Using the special tool and a suitable impact slide hammer, remove the pinion seal.
    Fig 17: Removing Pinion Seal
    G03434793Courtesy of FORD MOTOR CO.
  20. Remove the front axle drive pinion shaft oil slinger and the differential pinion bearing.
    Fig 18: Removing Front Axle Drive Pinion Shaft Oil Slinger & Differential Pinion Bearing
    G03434794Courtesy of FORD MOTOR CO.
  21. Remove the outer differential drive pinion bearing cup by tapping alternately on each side of the cup to prevent it from cocking in the bore.
    Fig 19: Removing Outer Differential Drive Pinion Bearing Cup
    G03434795Courtesy of FORD MOTOR CO.
  22. Remove the inner differential drive pinion bearing cup by tapping alternately on each side of the cup to prevent it from cocking in the bore.
    Fig 20: Removing Inner Differential Drive Pinion Bearing Cup
    G03434796Courtesy of FORD MOTOR CO.
  23. Remove the inner pinion bearing.
    1. Position the special tool under the bearing.
    2. Using a shop press, remove the inner pinion bearing.
    Fig 21: Removing Inner Pinion Bearing
    G03434797Courtesy of FORD MOTOR CO.
  24. Remove the pinion position shim from the differential pinion gear. Measure the pinion position shim thickness with a micrometer. Record the measurement.
    Fig 22: Removing Pinion Position Shim From Differential Pinion Gear
    G03434798Courtesy of FORD MOTOR CO.
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