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Differential Ring and Pinion - Rear Axle: Removal

WARNING: This page is about a different car, the 2004 Mercury Mountaineer and 2004 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the rear axle assembly. For additional information, refer to REAR AXLE ASSEMBLY .
  2. Remove the differential housing cover and drain the lubricant.
    3. CAUTION: Do not damage the aluminum differential housing while carrying out these procedures.
    Fig 1: Attaching Special Tools To Differential Housing
    G03190197Courtesy of FORD MOTOR CO.
  3. Using the special tools, mount the differential housing to a work bench.
    1. Attach the special tools to the differential housing with 4 differential housing cover bolts.
    2. Attach the special tools together with 2 3/8-inch x 1-1/2-inch bolts.
    4. CAUTION: RH spreader set screw must not be adjusted further down than flush or the spreader rocks and damages the seal and the housing.
    Fig 2: Installing Special Tool By Placing Spreader Pins In Hole
    G03190198Courtesy of FORD MOTOR CO.
  4. Install the special tool by placing the spreader pins in the hole in the housing spreader adapters.
  5. Assemble the special tools.
    1. Install the special tool.
    2. Attach the special tool and position the tip in the housing spreader adapter hole.
    Fig 3: Assembling Special Tools
    G03190199Courtesy of FORD MOTOR CO.
    6. CAUTION: Overspreading can damage the differential housing.
    NOTE: Tighten and loosen the differential carrier spreader screw to normalize the housing spreader adapters prior to taking the final dial indicator reading.
    Fig 4: Spreading Differential Housing To Specification
    G03190200Courtesy of FORD MOTOR CO.
  6. Spread the differential housing to the specification.
    1. Adjust the special tool to zero.
    2. Tighten the screw until the differential housing is spread to the specification.
    3. Remove the special tool.
    7. CAUTION: Mark the position and location of the differential bearing caps as the arrows may not be visible. Always install the differential bearing caps in their original locations and positions.
    Fig 5: Removing Differential Bearing Caps
    G03190201Courtesy of FORD MOTOR CO.
  7. Remove the differential bearing caps.
    1. Remove the differential bearing cap bolts.
    2. Remove the differential bearing caps.
    8. CAUTION: Use wood blocks to avoid damaging the differential housing.
    Fig 6: Removing Differential Assembly
    G03190202Courtesy of FORD MOTOR CO.
  8. Remove the differential assembly.
    1. Position wood blocks at the top and bottom of the differential assembly.
    2. Pry the differential assembly and the differential bearing shims out of the differential housing.
    3. Remove the special tool.
  9. Remove the 10 ring gear bolts.
    Fig 7: Removing Ring Gear Bolts
    G03190203Courtesy of FORD MOTOR CO.
    10. CAUTION: Do not damage the ring gear bolt hole threads.
  10. Insert a punch in the ring gear bolt holes and drive the differential ring gear off.
    11. WARNING: The speed sensor ring cannot be reused once removed. Remove the speed sensor ring only if damaged.
  11. If necessary, remove the speed sensor ring.
  12. Using the special tools, remove the differential bearings.
    Fig 8: Removing Differential Bearings Using The Special Tools
    G03190204Courtesy of FORD MOTOR CO.
  13. Using the special tool, hold the pinion flange to remove and discard the pinion nut.
    Fig 9: Holding Pinion Flange Using Special Tool
    G03190205Courtesy of FORD MOTOR CO.
  14. Using the special tool, remove the pinion flange.
    Fig 10: Removing Pinion Flange Using Special Tool
    G03190206Courtesy of FORD MOTOR CO.
  15. Use a screwdriver to force up the metal flange of the drive pinion oil seal. Install gripping pliers and strike with a hammer to remove the drive pinion oil seal.
    Fig 11: Removing Drive Pinion Oil Seal
    G03190207Courtesy of FORD MOTOR CO.
  16. Remove the drive pinion oil seal deflector, drive pinion oil seal slinger, the outer pinion bearing and the drive pinion collapsible spacer.
  17. Using the special tool and a soft-faced hammer, remove the differential pinion gear from the differential housing.
    Fig 12: Removing Differential Pinion Gear From Differential Housing
    G03190208Courtesy of FORD MOTOR CO.
  18. Using a brass drift and a hammer, remove the differential drive pinion bearing cups from the differential housing. Tap alternately on each side of the cup to prevent them from cocking in the bore.
    Fig 13: Removing Differential Drive Pinion Bearing Cups
    G03190209Courtesy of FORD MOTOR CO.
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