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Home >> Ford >> 2000 >> Contour SE, 2.0 3, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 453 (Front Drive Axle/Differential - DANA 35) >> Removal And Installation >> Differential Ring and Pinion >> Removal

Differential Ring and Pinion: 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.
  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: Connecting Axle Assembly To Special Tool
    G03272856Courtesy 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
      G03272857Courtesy 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
    G03272858Courtesy 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.
  6. Remove the differential bearing caps.
    1. Remove the bolts.
    2. Remove the differential bearing caps.
      Fig 4: Removing Differential Bearing Caps
      G03272859Courtesy of FORD MOTOR CO.
    7. CAUTION: The Housing Spreader Adapter bolts have a minimum thread engagement as specified.
    Fig 5: Installing Special Tool
    G03272860Courtesy 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: Positioning Clutch Housing Alignment Adapter Needle In Housing Spreader Adapter Hole
      G03272861Courtesy of FORD MOTOR CO.
    9. CAUTION: Over spreading can damage the differential housing.
  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.
      Fig 7: Spreading Differential Housing
      G03272862Courtesy of FORD MOTOR CO.
    10. CAUTION: Use wood blocks to avoid damaging the differential housing.
  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.
      Fig 8: Removing Differential Assembly From Differential Housing
      G03272863Courtesy of FORD MOTOR CO.
  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 Bolts And Differential Ring Gear
      G03272864Courtesy of FORD MOTOR CO.
  12. Assemble the special tools.
    Fig 10: Assembling Special Tools
    G03272865Courtesy of FORD MOTOR CO.
  13. Position the special tool on the differential bearing.
    Fig 11: Positioning Special Tool On Differential Bearing
    G03272866Courtesy of FORD MOTOR CO.
  14. Using the special tool, remove the differential bearings.
    Fig 12: Removing Differential Bearings
    G03272867Courtesy of FORD MOTOR CO.
  15. Use the special tool to hold the flange while removing the nut.
    Fig 13: Holding Flange
    G03272868Courtesy of FORD MOTOR CO.
  16. Using the special tool, remove the pinion flange.
    Fig 14: Removing Pinion Flange
    G03272869Courtesy of FORD MOTOR CO.
    17. 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.
  17. 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 15: Removing Pinion From Differential Housing
      G03272870Courtesy of FORD MOTOR CO.
  18. Using the special tool and a suitable impact slide hammer, remove the pinion seal.
    Fig 16: Removing Pinion Seal
    G03272871Courtesy of FORD MOTOR CO.
  19. Remove the front axle drive pinion shaft oil slinger and the differential pinion bearing.
    Fig 17: Removing Front Axle Drive Pinion Shaft Oil Slinger And Differential Pinion Bearing
    G03272872Courtesy of FORD MOTOR CO.
  20. 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 18: Removing Outer Differential Drive Pinion Bearing Cup
    G03272873Courtesy of FORD MOTOR CO.
  21. 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 19: Removing Inner Differential Drive Pinion Bearing Cup
    G03272874Courtesy of FORD MOTOR CO.
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