Differential Case: Removal

WARNING: This page is about a different car, the 2002 Ford RV Cutaway, 2002 Ford Econoline, 2002 Ford E550 Super Duty, 2002 Ford E450 Super Duty, and 2002 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

Remove the axle shafts (4234). For additional information, 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
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: Checking Ring Gear Backface Runout

Courtesy of FORD MOTOR CO.

Position the special tool, and inspect ring gear backlash and 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.

Fig 3: Removing Bearing Caps

Courtesy of FORD MOTOR CO.

Loosen the differential case.
1. Remove the bolts.
2. Remove the bearing caps.
To simplify removal, fabricate two differential case retaining straps from metal stock as shown.

Fig 4: Identifying Retaining Straps Dimensions
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

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 bolts.

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

CAUTION: Care should be taken not to damage the 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 clips and shims, in the carrier.
2. Install the differential bearing caps.
3. Install the differential bearing cap bolts.
  
  Fig 8: Installing Differential Bearing Cap Bolts
  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. Install the special tool.
Fig 9: Installing Special Tool
Courtesy of FORD MOTOR CO.

NOTE: If runout is within specification, install a new ring gear and pinion. If runout exceeds specification, the 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 a new differential case and the differential bearings.

Fig 10: Measuring Differential Case Runout

Courtesy of FORD MOTOR CO.

Measure the differential case runout without the ring gear.
1. Rotate the differential case.
2. Check and note the differential case runout.
Using the special tools, remove the differential case from the rear axle housing, and remove the differential bearings.

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

Fig 12: Installing New Differential Bearings With Special Tool
Courtesy of FORD MOTOR CO.
Measure the differential case runout without the ring gear.
- Check the case 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, a new differential case must be installed.
Fig 13: Measuring Differential Case Runout
Courtesy of FORD MOTOR CO.