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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 383 (Rear Drive Axle/Differential 7.5-Inch Ring Gear) >> In-Vehicle Repair >> Differential Case >> Removal

Differential Case: Removal

WARNING: This page is about a different car, the 2002 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the axle shafts. For additional information, refer to AXLE SHAFT  .
  2. Wipe the lubricant from the internal working parts and visually inspect the parts for wear or damage.
  3. Rotate the differential case to see if there is any roughness which would indicate damaged bearings or gears.
    Fig 1: Rotating Differential Assembly
    G03434249Courtesy of FORD MOTOR CO.
    4. 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 Backlash & Ring Gear Backface Runout
    G03434250Courtesy of FORD MOTOR CO.
  4. Position the special tool(s) and inspect ring gear backlash and ring gear backface runout.
    5. 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
    G03434251Courtesy of FORD MOTOR CO.
  5. Loosen the differential case.
    1. Remove the four bearing cap bolts.
    2. Remove the two bearing caps.
    6. 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 4: Removing Differential Assembly From Differential Housing
    G03434252Courtesy of FORD MOTOR CO.
  6. Using a pry bar and wood block, pry the differential case from the rear axle housing.
  7. Remove the 10 ring gear bolts.
    Fig 5: Removing Ring Gear Bolts
    G03434253Courtesy of FORD MOTOR CO.
    8. CAUTION: Care should be taken not to damage the ring bolt hole threads.
    NOTE: The anti-lock speed sensor ring cannot be reused once removed.
    Fig 6: Removing Ring Gear
    G03434254Courtesy of FORD MOTOR CO.
  8. Insert a punch in the bolt holes and drive off the ring gear and, if necessary, the anti-lock speed sensor ring.
  9. Install the differential case.
    • Position the differential case assembly, including the bearing cups and shims, in the rear axle housing. Install the differential bearing caps and the differential bearing cap bolts.
    Fig 7: Installing Bearing Caps & Bolts
    G03434255Courtesy of FORD MOTOR CO.
  10. Position the special tool.
    1. Rotate the differential case to make sure the differential bearings are correctly seated.
    2. Position the special tool.
    Fig 8: Positioning Special Tool
    G03434256Courtesy of FORD MOTOR CO.
  11. Rotate the differential case and measure the differential case runout without the ring gear.
    • If runout is less than the 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 new differential case and differential bearings.
    Fig 9: Measuring Differential Case Runout
    G03434257Courtesy of FORD MOTOR CO.
  12. Remove the differential case from the rear axle housing and remove the differential bearings using the special tools.
    Fig 10: Removing Differential Bearings
    G03434258Courtesy of FORD MOTOR CO.
  13. Using the special tool, install the new differential bearings on the differential case.
    Fig 11: Installing Differential Bearings
    G03434259Courtesy of FORD MOTOR CO.
  14. Position the differential case assembly, including the bearing cups and shims in the rear axle housing.
    • Tighten bearing caps to specification.
    Fig 12: Installing Bearing Caps & Bolts
    G03434260Courtesy of FORD MOTOR CO.
  15. Measure the differential case runout without the ring gear. Check the case runout again with the new differential bearings.
    • If the runout is now less than 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
    G03434261Courtesy of FORD MOTOR CO.
  16. Remove differential case from the rear axle housing.
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