Differential Carrier: Removal

WARNING: This page is about a different car, the 2007 Ford Pickup and 2007 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 AND LIFTING article.
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 article.

Fig 1: Bearing Cap Location Marks

Courtesy of FORD MOTOR CO.

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.

Remove the 4 bolts and the 2 bearing caps.

Fig 2: Using Special Tool To Spread Differential Housing

Courtesy of FORD MOTOR CO.

CAUTION: Do not spread the differential housing more than specified or damage to the housing may occur.

Using the special tools, spread the differential housing.

Fig 3: Removing Differential Carrier From Differential Housing

Courtesy of FORD MOTOR CO.

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.

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

Remove the differential assembly with the bearing cups.

Fig 4: Outboard Spacers

Courtesy of FORD MOTOR CO.

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.