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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 299 (Front Drive Axle/Differential - Ford 8.8-Inch -- F150) >> Disassembly And Assembly >> Axle-Front Drive >> Disassembly

Axle-Front Drive: Disassembly

WARNING: This page is about a different car, the 2002 Ford Pickup, 2001 Ford Pickup, and 2000 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the front drive axle assembly. Refer to the AXLE ASSEMBLY-Front Drive .
  2. Remove the vacuum control shield.
    • Remove the three bolts.
    • Remove the shield.
  3. Remove the differential housing cover (3N136).
    1. Remove the drain plug (390943).
    2. Drain the fluid.
    3. Remove the bolts.
    4. Remove the differential housing cover.
      Fig 1: Removing Differential Housing Cover
      G02187120Courtesy of FORD MOTOR CO.
    4. CAUTION: The fixture mounting bolts must have the minimum specified thread engagement in the carrier.
    Fig 2: Installing Holding Fixture
    G02187121Courtesy of FORD MOTOR CO.
  4. Install the special tool.
  5. Unseat the clutch shaft rod boot (7W082).
    Fig 3: Unseating Clutch Shaft Rod Boot
    G02187122Courtesy of FORD MOTOR CO.
  6. Remove the E-ring.
    Fig 4: Removing E-Ring
    G02187123Courtesy of FORD MOTOR CO.
  7. Disconnect the front axle actuator motor assembly (7G360).
    1. Fully extend the actuator motor shaft.
    2. Plug the vacuum ports.
    3. Pull outward on the front axle actuator motor assembly.
    4. Push the front axle actuator motor assembly to disconnect the shift lever (7K336) from the slot in the actuator motor shaft.
      Fig 5: Disconnecting Front Axle Actuator Motor Assembly
      G02187124Courtesy of FORD MOTOR CO.
  8. Remove the clutch shaft rod boot, and the front axle actuator motor assembly.
    1. Remove the clutch shaft rod boot.
    2. Remove the front axle actuator motor assembly.
      Fig 6: Removing Clutch Shaft Rod Boot & Front Axle Actuator Motor Assembly
      G02187125Courtesy of FORD MOTOR CO.
  9. Remove the axle housing tube (3B210).
    Fig 7: Removing Axle Housing Tube
    G02187126Courtesy of FORD MOTOR CO.
  10. Remove the thrust washer (3N126).
    Fig 8: Removing Thrust Washer
    G02187127Courtesy of FORD MOTOR CO.
  11. Remove the axle cluster gear shaft (7L253).
    Fig 9: Removing Axle Cluster Gear Shaft
    G02187128Courtesy of FORD MOTOR CO.
    12. CAUTION: Use a vise with soft jaws.
  12. Using the special tool, remove the pilot bearing assembly (3N106) from the axle cluster gear shaft.
    1. Position the axle cluster gear shaft in the vise.
    2. Using the special tool, remove the pilot bearing assembly.
      Fig 10: Removing Pilot Bearing Assembly
      G02187129Courtesy of FORD MOTOR CO.
  13. Lift the shift lever, and remove the coupler shift selector gear (7R262).
    Fig 11: Removing Coupler Shift Selector Gear
    G02187130Courtesy of FORD MOTOR CO.
    14. NOTE: There is enough clearance in the casting to remove the manual shaft retaining pin (7G100).
  14. If necessary, remove the shift lever and the clutch fork (3N139).
    • Drive the manual shaft retaining pin through the clutch fork.
    • Remove the shift lever and the clutch fork.
      Fig 12: Removing Shift Lever & Clutch Fork
      G02187131Courtesy of FORD MOTOR CO.
  15. Remove and discard the O-ring.
    Fig 13: Identifying O-Ring
    G02187132Courtesy of FORD MOTOR CO.
  16. Remove the axle shaft (3A381).
    1. Remove the snap ring.
    2. Remove the axle shaft.
      Fig 14: Removing Axle Shaft
      G02187133Courtesy of FORD MOTOR CO.
    17. CAUTION: The housing spreader adapter bolts must have the minimum specified thread engagement in the carrier.
    Fig 15: Installing Spreader Adapters
    G02187134Courtesy of FORD MOTOR CO.
  17. Install the special tools.
  18. Position the special tool on the spreader adapters.
    Fig 16: Positioning Special Tool On Spreader Adapters
    G02187135Courtesy of FORD MOTOR CO.
  19. If necessary, adjust the special tool to provide clearance for the shift lever.
    Fig 17: Identifying Shift Lever Clearance
    G02187136Courtesy of FORD MOTOR CO.
  20. Install the special tools.
    • Position the adapter tip in the spreader adapter hole.
      Fig 18: Installing Special Tools
      G02187137Courtesy of FORD MOTOR CO.
    21. CAUTION: Overspreading can damage the axle housing.
  21. Spread the axle housing to the specification.
    1. Adjust the special tool to zero.
    2. Tighten the housing spreader screw to spread the axle housing to the specification.
    3. Remove the Dial Indicator.
      Fig 19: Spreading Axle Housing To Specification
      G02187138Courtesy of FORD MOTOR CO.
    22. CAUTION: Mark the differential bearing caps (4224) Top or Bottom and LH or RH appropriately before removing them. Always install the bearing caps in their original place and position.
  22. Mark and remove the differential bearing caps.
    1. Remove the bolts.
    2. Remove the differential bearing caps.
      Fig 20: Removing Differential Bearing Caps
      G02187139Courtesy of FORD MOTOR CO.
    23. CAUTION: Use wood blocks to avoid axle housing damage.
  23. Remove the differential assembly from the axle housing.
    1. Position the wood blocks.
    2. Position and push down on the two pry bars.
    3. Remove the differential assembly.
    4. Remove the special tool.
      Fig 21: Removing Differential Assembly From Axle Housing
      G02187140Courtesy of FORD MOTOR CO.
  24. Index-mark the axle universal joint flange (4858) to the pinion stem.
    Fig 22: Indexing Axle Universal Joint Flange To Pinion Stem
    G02187141Courtesy of FORD MOTOR CO.
  25. Install the special tool, and loosen, but do not remove the pinion nut.
    Fig 23: Loosening Pinion Nut
    G02187142Courtesy of FORD MOTOR CO.
  26. With the pinion nut still engaged by a few threads, use the special tool to separate the axle universal joint flange from the pinion gear (3N175).
    Fig 24: Separating Axle Universal Joint Flange From Pinion Gear
    G02187143Courtesy of FORD MOTOR CO.
  27. Remove the nut and the flange.
  28. Using the special tool and a soft hammer, remove the pinion gear.
    1. Install the special tool.
    2. Hold the pinion gear inside the carrier housing.
    3. Using a soft face hammer, remove the pinion gear from the carrier housing.
      Fig 25: Removing Pinion Gear
      G02187144Courtesy of FORD MOTOR CO.
  29. Discard the drive pinion collapsible spacer (4662).
    Fig 26: Identifying Drive Pinion Collapsible Spacer
    G02187145Courtesy of FORD MOTOR CO.
    30. CAUTION: Do not damage the carrier housing while removing the pinion seal.
  30. Remove the pinion seal (3N134) and slinger (386989).
    • Pry up on the seal flange. Install gripping pliers, and strike with a hammer to remove the seal.
      Fig 27: Removing Pinion Seal & Slinger
      G02187146Courtesy of FORD MOTOR CO.
  31. Remove the outer pinion bearing (4621).
  32. Using the special tools, remove the inner pinion bearing cup (4628).
    Fig 28: Removing Inner Pinion Bearing Cup
    G02187147Courtesy of FORD MOTOR CO.
    33. NOTE: The pinion bearing oil baffle (4631) aids in bearing lubrication. Normally, it is not necessary to remove the baffle.
    Fig 29: Removing Pinion Bearing Oil Baffle
    G02187148Courtesy of FORD MOTOR CO.
  33. If necessary, remove the pinion bearing oil baffle.
  34. Remove the outer pinion bearing cup (4616) by tapping alternately on each side to prevent the cup from cocking.
    Fig 30: Identifying Outer Pinion Bearing Cup
    G02187149Courtesy of FORD MOTOR CO.
  35. Using the special tool and a suitable press, remove the pinion bearing (4630).
    Fig 31: Removing Pinion Bearing
    G02187150Courtesy of FORD MOTOR CO.
    36. NOTE: A drive pinion bearing adjustment shim (4663) 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 32: Removing Drive Pinion Bearing Adjustment Shim
    G02187151Courtesy of FORD MOTOR CO.
  36. Remove and measure the drive pinion bearing adjustment shim.
  37. Remove the ten bolts and the ring gear (3A397).
    • Use a drift punch to separate the ring gear from the differential case (4205).
      Fig 33: Removing Ring Gear
      G02187152Courtesy of FORD MOTOR CO.
  38. Using the special tools, remove the differential bearings (4221).
    Fig 34: Removing Differential Bearings
    G02187153Courtesy of FORD MOTOR CO.
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