Differential Ring And Pinion: 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.

Remove the differential carrier. For additional information, refer to DIFFERENTIAL CARRIER .
Remove the ring gear bolts.

Fig 1: Identifying 12 Differential Ring Gear Bolts
Courtesy of FORD MOTOR CO.

CAUTION: Care should be taken not to damage the ring bolt hole threads.

NOTE: The anti-lock speed sensor ring cannot be reused once removed.

Fig 2: Driving Off Ring Gear

Courtesy of FORD MOTOR CO.

Insert a punch in the bolt holes. Drive off the ring gear and, if necessary, the anti-lock speed sensor ring.
Position the special tool.

Fig 3: Positioning Special Tool
Courtesy of FORD MOTOR CO.
Using 2 wrenches, remove the differential bearing.
- Repeat the procedure for the other differential bearing.
  
  Fig 4: Removing Differential Bearing Using Wrenches
  Courtesy of FORD MOTOR CO.
Using the special tool, install the new differential bearings on the differential case.

Fig 5: Pressing Differential Bearings On Differential Case Using Special Tool
Courtesy of FORD MOTOR CO.
To maintain driveline balance, index-mark the driveshaft flange and the pinion flange.

Fig 6: Identifying Index-Mark On Driveshaft Flange To Pinion Flange
Courtesy of FORD MOTOR CO.
Remove the 4 bolts.

Fig 7: Identifying Driveshaft Flange and Rear Axle Pinion Flange Bolts And Alignment Marks
Courtesy of FORD MOTOR CO.

CAUTION: The driveshaft flange fits tightly on the pinion flange. Pry only in the area shown, with a suitable tool, to disconnect the flange.

CAUTION: It may be necessary to tap the driveshaft yoke with a plastic or rubber soft-faced hammer if a pry area is not on the driveshaft yoke.

Fig 8: Disconnecting Driveshaft Flange Yoke From Pinion Flange

Courtesy of FORD MOTOR CO.

Using a suitable tool as shown, disconnect the driveshaft flange from the pinion flange and support the driveshaft using mechanic's wire.
Use the special tool to prevent the flange from turning while removing the lock nut and washer.

Fig 9: Holding Pinion Flange With Special Tool
Courtesy of FORD MOTOR CO.
Using the special tool, remove the pinion flange.

Fig 10: Removing Pinion Flange Using Special Tool
Courtesy of FORD MOTOR CO.
Force up on the metal flange of the rear axle drive pinion seal. Install gripping pliers to the seal flange and strike with a hammer until the rear axle drive pinion seal is removed.
- Remove the oil slinger and the outer pinion bearing.
  
  Fig 11: Removing Drive Pinion Oil Seal
  Courtesy of FORD MOTOR CO.
Install the special tool and, with a soft-faced hammer, drive the pinion out of the front bearing cone and remove it through the rear of the housing.

Fig 12: Identifying Special Tool To Remove Drive Pinion Gear
Courtesy of FORD MOTOR CO.
Using a brass drift, remove the pinion bearing cups by tapping alternately on opposite sides of the cups.

Fig 13: Identifying Pinion Bearing Cups
Courtesy of FORD MOTOR CO.