Differential Carrier: 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.
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.