Differential Bearings: 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: 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.

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.
Attach the axle assembly to the special tool.

Fig 1: Attaching Axle Assembly To Special Tool
Courtesy of FORD MOTOR CO.

NOTE: Place a suitable drain pan under the axle.

Remove the differential housing cover.
1. Remove the bolts.
2. Remove the differential housing cover.
  
  Fig 2: Removing Differential Housing Cover
  Courtesy of FORD MOTOR CO.
Drain the axle lubricant from the differential housing.
Remove the axle shaft using a jerking motion.

Fig 3: Removing Axle Shaft
Courtesy of FORD MOTOR CO.

CAUTION: The matched numbers or letters stamped on both of the differential bearing caps and the differential housing must correspond during assembly.

Remove the differential bearing caps.
1. Remove the bolts.
2. Remove the differential bearing caps.
  
  Fig 4: Removing Differential Bearing Caps
  Courtesy of FORD MOTOR CO.

CAUTION: The Housing Spreader Adapter bolts have a minimum thread engagement as specified.

Fig 5: Installing Special Tool

Courtesy of FORD MOTOR CO.

Install the special tool.
Install the special tools.
- Position the Clutch Housing Alignment Adapter needle in the Housing Spreader Adapter hole.
  
  Fig 6: Positioning Clutch Housing Alignment Adapter Needle In Housing Spreader Adapter Hole
  Courtesy of FORD MOTOR CO.

CAUTION: Over spreading can damage the differential housing.

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.
  
  Fig 7: Spreading Differential Housing
  Courtesy of FORD MOTOR CO.

CAUTION: Use wood blocks to avoid damaging the differential housing.

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.
  
  Fig 8: Removing Differential Assembly From Differential Housing
  Courtesy of FORD MOTOR CO.
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
  Courtesy of FORD MOTOR CO.
Assemble the special tools.

Fig 10: Assembling Special Tools
Courtesy of FORD MOTOR CO.
Position the special tool on the differential bearing.

Fig 11: Positioning Special Tool On Differential Bearing
Courtesy of FORD MOTOR CO.
Using the special tool, remove the differential bearings.

Fig 12: Removing Differential Bearings
Courtesy of FORD MOTOR CO.
Index -mark the pinion flange and the pinion stem.

Fig 13: Index Marking Pinion Flange And Pinion Stem
Courtesy of FORD MOTOR CO.
Use the special tool to hold the flange while removing the nut.

Fig 14: Holding Pinion Flange
Courtesy of FORD MOTOR CO.
Using the special tool, remove the pinion flange.

Fig 15: Removing Pinion Flange
Courtesy of FORD MOTOR CO.

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.

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.
  
  Fig 16: Removing Pinion From Differential Housing
  Courtesy of FORD MOTOR CO.
Using the special tool and a suitable impact slide hammer, remove the pinion seal.

Fig 17: Removing Pinion Seal
Courtesy of FORD MOTOR CO.
Remove the front axle drive pinion shaft oil slinger and the differential pinion bearing.

Fig 18: Removing Front Axle Drive Pinion Shaft Oil Slinger And Differential Pinion Bearing
Courtesy of FORD MOTOR CO.
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
Courtesy of FORD MOTOR CO.
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
Courtesy of FORD MOTOR CO.
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
  Courtesy of FORD MOTOR CO.
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
Courtesy of FORD MOTOR CO.