Disassembly And Assembly: Axle: Disassembly

WARNING: This page is about a different car, the 2003 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: Many components and surfaces in the axle are precision machined. Careful handling during disassembly, cleaning, inspection, and assembly will prevent unnecessary damage to machined surfaces.

Remove the front drive axle assembly from the vehicle. For additional information, refer to AXLE ASSEMBLY-FRONT .
Attach the axle assembly to the special tool.

Fig 1: Attaching Axle Assembly To Special Tool
Courtesy of FORD MOTOR CO.

NOTE: Place a suitable drain pan under the axle.

Remove the differential housing cover.
1. Remove the bolts.
2. Remove the differential housing cover.
  
  Fig 2: Removing Differential Housing Cover
  Courtesy of FORD MOTOR CO.
Drain the axle lubricant from the differential housing.
Remove the axle shaft using a jerking motion.

Fig 3: Removing Axle Shaft Using A Jerking Motion
Courtesy of FORD MOTOR CO.
Using the special tool and a suitable impact slide hammer, remove the axle shaft oil seal.

Fig 4: Removing Axle Shaft Oil Seal
Courtesy of FORD MOTOR CO.
Using the special tool and a suitable impact slide hammer, remove the axle shaft bearing.

Fig 5: Removing Axle Shaft Bearing
Courtesy of FORD MOTOR CO.
Using the special tool and a suitable impact slide hammer, remove the axle shaft oil seal.

Fig 6: Removing Axle Shaft Oil Seal
Courtesy of FORD MOTOR CO.
Using the special tool and a suitable impact slide hammer, remove the axle tube bearing.

Fig 7: Removing Axle Tube Bearing
Courtesy of FORD MOTOR CO.

CAUTION: The matched numbers or letters stamped on both of the differential bearing caps and the differential housing must correspond during assembly.

Remove the differential bearing caps.
1. Remove the bolts.
2. Remove the differential bearing caps.
  
  Fig 8: Removing Differential Bearing Caps
  Courtesy of FORD MOTOR CO.

CAUTION: The Housing Spreader Adapter bolts have a minimum thread engagement as specified.

Fig 9: Installing Special Tool

Courtesy of FORD MOTOR CO.

Install the special tool.
Install the special tools.
- Position the Clutch Housing Alignment Adapter needle in the Housing Spreader Adapter hole.
  
  Fig 10: Positioning Clutch Housing Alignment Adapter Needle In Housing Spreader Adapter Hole
  Courtesy of FORD MOTOR CO.

CAUTION: Over spreading can damage the differential housing.

Spread the differential housing to the specification.
1. Adjust the special tool to zero.
2. Tighten the Differential Carrier Spreader screw to spread the differential housing to the specification.
3. Remove the Dial Indicator with Bracketry and the Clutch Housing Alignment Adapter.
  
  Fig 11: Spreading Differential Housing
  Courtesy of FORD MOTOR CO.

CAUTION: Use wood blocks to avoid damaging the differential housing.

Remove the differential assembly from the differential housing.
1. Position the wood blocks.
2. Push downward on the pry bars.
3. Remove the differential assembly.
4. Remove the special tool.
  
  Fig 12: Removing Differential Assembly From Differential Housing
  Courtesy of FORD MOTOR CO.
Measure the pinion bearing preload.
- Using a Nm (pound-inch) torque wrench, measure the torque required to maintain pinion rotation. Record the measurement.
  
  Fig 13: Measuring Pinion Bearing Preload
  Courtesy of FORD MOTOR CO.
Index-mark the pinion flange and the pinion stem.

Fig 14: Index-Marking Pinion Flange & Pinion Stem
Courtesy of FORD MOTOR CO.
Use the special tool to hold the flange while removing the nut.

Fig 15: Using Special Tool To Hold Flange While Removing Nut
Courtesy of FORD MOTOR CO.
Using the special tool, remove the pinion flange.

Fig 16: Removing Pinion Flange
Courtesy of FORD MOTOR CO.

WARNING: The gear teeth have sharp edges. Handle the gear with care to avoid personal injury.

CAUTION: Never use a metal hammer on the pinion. Use a soft mallet to drive the pinion out of the differential housing.

Using a soft-face hammer, remove the pinion from the differential housing.
1. Hold the pinion inside the differential housing.
2. Use a soft-face hammer to remove the pinion from the differential housing.
  
  Fig 17: Removing Pinion From Differential Housing
  Courtesy of FORD MOTOR CO.
Using the special tool and a suitable impact slide hammer, remove the pinion seal.

Fig 18: Removing Pinion Seal
Courtesy of FORD MOTOR CO.
Remove the front axle drive pinion shaft oil slinger and the differential pinion bearing.

Fig 19: Removing Front Axle Drive Pinion Shaft Oil Slinger & Differential Pinion Bearing
Courtesy of FORD MOTOR CO.
Remove the outer differential drive pinion bearing cup by tapping alternately on each side of the cup to prevent it from cocking in the bore.

Fig 20: Removing Outer Differential Drive Pinion Bearing Cup
Courtesy of FORD MOTOR CO.
Remove the inner differential drive pinion bearing cup by tapping alternately on each side of the cup to prevent it from cocking in the bore.

Fig 21: Removing Inner Differential Drive Pinion Bearing Cup
Courtesy of FORD MOTOR CO.
Using the special tool and a suitable press, remove the differential pinion bearing.

Fig 22: Removing Differential Pinion Bearing
Courtesy of FORD MOTOR CO.
Remove the pinion position shim from the differential pinion gear. Measure the pinion position shim thickness with a micrometer. Record the measurement.

Fig 23: Removing Pinion Position Shim From Differential Pinion Gear
Courtesy of FORD MOTOR CO.
Remove the differential ring gear, the differential bearings, and if necessary, disassemble the differential case. For additional information, refer to DIFFERENTIAL CASE .