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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 Carrier >> Removal

Differential Carrier: 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
    G03434837Courtesy of FORD MOTOR CO.
  3. Remove the differential housing cover.
    1. Remove the bolts.
    2. Remove the differential housing cover.
    Fig 2: Removing Differential Housing Cover
    G03434838Courtesy of FORD MOTOR CO.
  4. Drain the axle lubricant from the differential housing.
  5. Remove the axle shaft using a jerking motion.
    Fig 3: Removing Axle Shaft
    G03434839Courtesy 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
    G03434840Courtesy 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
    G03434841Courtesy 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
    G03434842Courtesy of FORD MOTOR CO.
    9. CAUTION: Over spreading can damage the differential housing.
    Fig 7: Spreading Differential Housing To Specification
    G03434843Courtesy 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
    G03434844Courtesy 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.
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