Differential Case and Ring Gear - Conventional: Disassembly

WARNING: This page is about a different car, the 2006 Ford Pickup and 2006 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Remove the differential carrier. For additional information, refer to DIFFERENTIAL CARRIER .
Using the special tools, remove and discard the differential bearings.
- Place the left and right differential bearing shims with the respective outboard spacers.
  
  Fig 1: Removing Differential Bearings Using Special Tools
  Courtesy of FORD MOTOR CO.

NOTE: Whenever removing the differential ring gear bolts, always install new Grade 9 differential ring gear bolts.

Fig 2: Identifying Ring Gear

Courtesy of FORD MOTOR CO.

Remove 8 of the differential ring gear bolts. Leave 4 differential ring gear bolts loosely assembled, 90 degrees apart.
Tap each differential ring gear bolt head alternately with a rawhide or plastic hammer to loosen the differential ring gear. Remove the 4 differential ring gear bolts and the differential ring gear.
- Discard the differential ring gear bolts.
  
  Fig 3: Tapping Loosley Installed Bolts To Remove Ring Gear
  Courtesy of FORD MOTOR CO.

NOTE: Use a vise with brass jaws or wood blocks.

Place the differential case in a vise.
Using a suitable tool, drive out the differential pinion shaft lockpin.

Fig 4: Driving Out Differential Pinion Shaft Lockpin
Courtesy of FORD MOTOR CO.
Using a suitable tool, remove the differential pinion shaft.

Fig 5: Removing Differential Pinion Shaft
Courtesy of FORD MOTOR CO.
To remove the differential side gears and the differential pinion gears, rotate the differential side gears. The differential pinion gears will turn to the opening in the differential case.

Fig 6: Locating Differential Pinion And Side Gears
Courtesy of FORD MOTOR CO.
Remove the differential pinion gears and the differential pinion thrust washers.
Lift out the differential side gears and the differential side gear thrust washers.