Differential Case: Removal

WARNING: This page is about a different car, the 2002 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.

Remove the axle shafts (4234). Refer to AXLE SHAFT .
Wipe the lubricant from the internal working parts, and visually inspect the parts for wear or damage.
Rotate the differential case (4204) to see if there is any roughness which would indicate damaged bearings or gears.

Fig 1: Rotating Differential Case For Checking Any Roughness
Courtesy of FORD MOTOR CO.

NOTE: There is a space between the anti-lock speed sensor ring and the ring gear for measuring ring gear backface runout.

Fig 2: Measuring Ring Gear Backface Runout

Courtesy of FORD MOTOR CO.

Position the special tool and inspect the ring gear backface runout.

CAUTION: Mark the position of the bearing caps as arrows may not be visible. The bearing caps must be installed in their identical locations and positions.

Loosen the differential case.
1. Remove the bearing cap bolts.
2. Remove the bearing caps.
  
  Fig 3: Removing Bearing Caps
  Courtesy of FORD MOTOR CO.
Fabricate two differential case retaining straps from metal stock as shown.

Fig 4: Fabricating Two Differential Case Retaining Straps From Metal Stock
Courtesy of FORD MOTOR CO.

WARNING: Be careful not to allow the differential case to fall.

CAUTION: Place a wood block between the pry bar and the rear axle housing (4010) to protect the machined surface from damage.

Fig 5: Removing Differential Case From Rear Axle Housing

Courtesy of FORD MOTOR CO.

Use the pry bar and the wood block to remove the differential case from the rear axle housing.
Remove the differential ring gear bolts.

Fig 6: Removing Differential Ring Gear Bolts
Courtesy of FORD MOTOR CO.

CAUTION: Care should be taken not to damage the differential ring gear bolt hole thread.

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

Fig 7: Removing 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.
Install the differential case.
1. Position the differential case assembly, including bearing cups and shims, in the carrier.
2. Install the differential bearing caps.
3. Install the differential bearing cap bolts.
  
  Fig 8: Installing Differential Bearing Cap
  Courtesy of FORD MOTOR CO.
Position the special tool.
1. Rotate the differential case to make sure the differential bearings (4221) are correctly seated.
2. Position the special tool.
  
  Fig 9: Positioning Special Tool And Rotating Differential Case For Checking Proper Seating Of Differential Bearings
  Courtesy of FORD MOTOR CO.

NOTE: If runout is within specification, install a new differential ring gear and pinion. If runout exceeds the maximum specification shown, the differential ring gear is true and the concern is due to either a damaged differential case or differential bearings. Inspect the differential bearings. If the differential bearings are not damaged, install both the differential case and the differential bearings new.

Measure the differential case runout without the differential ring gear.
1. Rotate the differential case.
2. Check and note the differential case runout.
  
  Fig 10: Measuring Differential Case Runout Without Differential Ring Gear
  Courtesy of FORD MOTOR CO.
Remove the differential case from the rear axle housing, and remove the differential bearings using the special tools.

Fig 11: Removing Differential Bearings Using Special Tools
Courtesy of FORD MOTOR CO.
Using the special tool, install the new differential bearings on the differential case.

Fig 12: Installing Differential Bearings On Differential Case
Courtesy of FORD MOTOR CO.
Measure the differential case runout without the differential ring gear.
- Check the differential case flange runout again with the new differential bearings. If the runout is now within the specification shown, use the new differential bearings for assembly. If the runout is still excessive, the differential case is damaged and must be installed new.
  
  Fig 13: Measuring Differential Case Runout Without Differential Ring Gear
  Courtesy of FORD MOTOR CO.