Differential Carrier: Removal

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.

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
Remove the 10 differential housing cover bolts and the differential housing cover.
- Drain the lubricant from the rear axle.
Clean the gasket material from the differential housing cover and the differential housing.
Remove the axle shafts. For additional information, refer to WHEEL HUBS AND BEARINGS - FULL FLOATING AXLE - DANA .

NOTE: Note the positions of the mating letters stamped vertically and horizontally on the bearing caps and the differential housing before removing the bearing caps.

Fig 1: Locating Bearing Caps

Courtesy of FORD MOTOR CO.

Remove the 4 bolts and the 2 bearing caps.

CAUTION: Do not spread the differential housing more than specified.

Fig 2: Using Special Tool To Spread Differential Housing

Courtesy of FORD MOTOR CO.

Using the special tools, spread the differential housing.

CAUTION: It will be necessary to use large pry bars to remove the differential carrier from the differential housing. Do not damage the differential ring rear when carrying out this step.

CAUTION: Mark or tag the differential bearing cups, indicating from which side they were removed.

Fig 3: Locating Differential Assembly

Courtesy of FORD MOTOR CO.

Remove the differential assembly with the bearing cups.

NOTE: Mark or tag the outboard spacers indicating from which side they were removed.

Remove the outboard spacers.
- Inspect the spacers for nicks, bending and grooved conditions. Discard them if necessary.
  
  Fig 4: Identifying Outboard Spacers
  Courtesy of FORD MOTOR CO.