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Home >> Ford >> 2000 >> Contour SE, 2.0 3, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 451 (Rear Drive Axle/Differential - Ford 8.8" Ring Gear) >> In-Vehicle Repair >> Differential Case >> Removal

Differential Case: Removal

WARNING: This page is about a different car, the 2004 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION: Reinstall the differential pinion shaft (4211) and the bolt in the differential case (4204) after removing the axle shafts.
  1. Remove the axle shafts (4234). For additional information, refer to AXLE SHAFT .
  2. Wipe the lubricant from the internal working parts and inspect the parts for wear and damage.
  3. Rotate the differential assembly to check for roughness indicating bearing/gear damage.
    Fig 1: Rotating Differential Assembly To Check For Roughness
    G03272516Courtesy of FORD MOTOR CO.
    4. NOTE: There is a space between the anti-lock speed sensor ring (4B409) and the differential ring gear for measuring the differential ring gear backface runout.
    Fig 2: Measuring Differential Ring Gear Backface Runout
    G03272517Courtesy of FORD MOTOR CO.
  4. Using a suitable dial indicator and the special tool, measure and note the differential ring gear backface runout.
    5. CAUTION: Mark the position of the bearing caps, as the arrows may not be visible. Always install the bearing caps in their identical locations and positions.
  5. Remove the bearing caps.
    1. Remove the bolts.
    2. Remove the bearing caps.
      Fig 3: Removing Bearing Caps
      G03272518Courtesy of FORD MOTOR CO.
    6. WARNING: Do not allow the differential assembly to fall.
    CAUTION: Place a wood block between the pry bar and the differential housing (4141) to protect the machined surface from damage.
    Fig 4: Removing Differential Assembly From Differential Housing
    G03272519Courtesy of FORD MOTOR CO.
  6. Using a pry bar and a wood block, remove the differential assembly from the differential housing.
  7. Remove the bolts.
    Fig 5: Removing Ring Gear Bolts
    G03272520Courtesy of FORD MOTOR CO.
    8. CAUTION: Do not damage the differential ring gear bolt hole threads.
    CAUTION: If removing the anti-lock speed sensor ring, discard it, and install a new antilock speed sensor ring during installation.
    Fig 6: Removing Ring Gear
    G03272521Courtesy of FORD MOTOR CO.
  8. Insert a punch in the bolt holes, and drive off the differential ring gear and, if necessary, the anti -lock speed sensor ring.
  9. If the differential ring gear backface runout measurement, taken at the beginning of this procedure, did not exceed the specification, proceed to the appropriate procedure as necessary: Drive Pinion , DIFFERENTIAL CASE AND RING GEAR - Conventional  or DIFFERENTIAL CASE AND RING GEAR - Traction-Lok  or to Installation . If the differential ring gear backface runout measurement, taken at the beginning of this procedure, exceeded the specification, the cause may be a warped differential ring gear, differential case/differential bearing damage. Proceed as follows to verify the cause of the excessive runout.
  10. Position the differential assembly, including the differential bearing cups (4222) and differential bearing shims (4067), in the differential housing. Install the bearing caps and the bolts.
    Fig 7: Installing Bearing Caps And Bolts
    G03272522Courtesy of FORD MOTOR CO.
  11. Position the special tool.
    1. Rotate the differential case to verify that the differential bearings (4221) have seated correctly.
    2. Position the special tool.
      Fig 8: Position The Special Tool
      G03272523Courtesy of FORD MOTOR CO.
  12. Measure and note the differential case runout.
    • If the runout does not exceed the specification, install a new differential ring gear and pinion. For additional information, refer to DRIVE PINION  and to INSTALLATION .
    • If the runout exceeds the specification, the differential ring gear is true and the concern is due to either differential case/differential bearing damage. Proceed as follows.
      Fig 9: Measuring Differential Case Runout
      G03272524Courtesy of FORD MOTOR CO.
  13. Using the special tools, remove the differential bearings.
    Fig 10: Removing Differential Bearings
    G03272525Courtesy of FORD MOTOR CO.
  14. Using the special tool, install the new differential bearings.
    Fig 11: Installing New Differential Bearings
    G03272526Courtesy of FORD MOTOR CO.
  15. Position the differential assembly, including the differential bearing cups and differential bearing shims in the differential housing. Tighten bearing caps to specification.
    Fig 12: Tightening Bearing Caps To Specification Torque
    G03272527Courtesy of FORD MOTOR CO.
  16. Position the special tool.
    1. Rotate the differential case to verify that the differential bearings have seated correctly.
    2. Position the special tool.
      Fig 13: Installing The Special Tool
      G03272528Courtesy of FORD MOTOR CO.
  17. Measure the differential case runout.
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