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Disassembly And Assembly: Axle: Disassembly

WARNING: This page is about a different car, the 2007 Lincoln Mark LT and 2007 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the front drive axle assembly. For additional information, refer to Axle Assembly  in this article.
  2. Remove the 10 differential housing cover bolts and the differential housing cover.
    • Drain the fluid.
    Fig 1: Identifying Differential Housing Cover Bolts
    GF0003260Courtesy of FORD MOTOR CO.
    3. NOTE: The fixture mounting bolts must have the minimum specified thread engagement in the carrier.
    Fig 2: Installing Special Tool
    GF0003261Courtesy of FORD MOTOR CO.
  3. Install the special tool.
  4. Using a suitable axle shaft remover, remove the RH and LH axle shafts.
    Fig 3: Removing RH And LH Axle Shafts
    GF0003263Courtesy of FORD MOTOR CO.
  5. Remove the 4 bolts and the axle housing tube.
    Fig 4: Identifying Axle Housing Tube Bolts
    GF0003313Courtesy of FORD MOTOR CO.
    6. NOTE: The housing spreader adapter bolts must have the minimum specified thread engagement in the carrier.
    Fig 5: Installing Special Tools
    GF0003264Courtesy of FORD MOTOR CO.
  6. Install the special tools.
  7. Position the special tool on the spreader adapters.
    Fig 6: Positioning Special Tool On Spreader Adapters
    GF0003213Courtesy of FORD MOTOR CO.
  8. Install the special tools.
    • Position the adapter tip in the spreader adapter hole.
    Fig 7: Installing Special Tools
    GF0003302Courtesy of FORD MOTOR CO.
    9. CAUTION: Overspreading can damage the axle housing.
    Fig 8: Spreading Axle Housing To Specification
    GF0003303Courtesy of FORD MOTOR CO.
  9. Spread the axle housing to the specification.
    • Adjust the special tool to zero.
    • Tighten the housing spreader screw to spread the axle housing to the specification.
    • Remove the special tool.
    10. CAUTION: Mark the differential bearing caps Top or Bottom and LH or RH appropriately before removing them or damage to the component may occur. Always install the bearing caps in their original place and position.
    Fig 9: Identifying Differential Bearing Caps
    GF0003267Courtesy of FORD MOTOR CO.
  10. Mark and remove the 2 differential bearing caps.
    • Remove the 4 bolts.
    • Remove the 2 differential bearing caps.
    11. CAUTION: Use wood blocks to avoid axle housing damage.
    Fig 10: Removing Differential Assembly From Axle Housing
    G03912955Courtesy of FORD MOTOR CO.
  11. Remove the differential assembly from the axle housing.
    • Position the wood blocks.
    • Position and push down on the 2 pry bars.
    • Remove the differential assembly.
    • Remove the special tool.
  12. Install the special tool and loosen, but do not remove, the pinion nut.
    Fig 11: Holding Pinion Flange Using Special Tool
    G03928261Courtesy of FORD MOTOR CO.
  13. Index-mark the axle U-joint flange to the pinion stem.
    Fig 12: Index-Marking Axle U-Joint Flange To Pinion Stem
    GF0003298Courtesy of FORD MOTOR CO.
  14. With the pinion nut still engaged by a few threads, use the special tool to separate the axle U-joint flange from the pinion gear.
  15. Remove the nut and the flange.
    • Discard the pinion nut.
    Fig 13: Removing Pinion Flange
    GF0003227Courtesy of FORD MOTOR CO.
  16. Using the special tool and a soft hammer, remove the pinion gear.
    Fig 14: Removing Pinion Gear
    GF0003268Courtesy of FORD MOTOR CO.
  17. Discard the drive pinion collapsible spacer.
    Fig 15: Identifying Drive Pinion Collapsible Spacer
    GF0003269Courtesy of FORD MOTOR CO.
    18. CAUTION: Do not damage the carrier housing while removing the pinion seal.
    Fig 16: Removing Drive Pinion Oil Seal
    G03878521Courtesy of FORD MOTOR CO.
  18. Remove the pinion seal and slinger.
    • Pry up on the seal flange. Install gripping pliers, and strike with a hammer to remove the seal.
  19. Remove the outer pinion bearing.
  20. Using the special tools, remove the inner pinion bearing cup.
    Fig 17: Removing Inner Pinion Bearing Cup
    GF0003270Courtesy of FORD MOTOR CO.
    21. NOTE: The pinion bearing oil baffle aids in bearing lubrication. Normally, it is not necessary to remove the baffle.
    Fig 18: Identifying Pinion Bearing Oil Baffle
    GF0003271Courtesy of FORD MOTOR CO.
  21. If necessary, remove the pinion bearing oil baffle.
  22. Remove the outer pinion bearing cup by tapping alternately on each side to prevent the cup from cocking.
    Fig 19: Identifying Outer Pinion Bearing Cup
    GF0003272Courtesy of FORD MOTOR CO.
  23. Using the special tool and a suitable press, remove the pinion bearing.
    Fig 20: Inner Pinion Bearing And Special Tool
    G03878658Courtesy of FORD MOTOR CO.
    24. NOTE: A drive pinion bearing adjustment shim sits under the pinion bearing. Use a micrometer to measure the shim thickness. Record the measurement for comparison to the shim gauge reading taken prior to installing the pinion bearing.
    Fig 21: Identifying Drive Pinion Bearing Adjustment Shim
    GF0003314Courtesy of FORD MOTOR CO.
  24. Remove and measure the drive pinion bearing adjustment shim.
  25. Remove the 10 bolts and the ring gear.
    • Use a drift punch to separate the ring gear from the differential case.
    • Discard the ring gear bolts.
    Fig 22: Identifying Differential Ring Gear Bolts
    GF0003217Courtesy of FORD MOTOR CO.
  26. Using the special tools, remove the RH and LH differential bearings.
    Fig 23: Removing Differential Bearing Using Special Tools
    G04583104Courtesy of FORD MOTOR CO.
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