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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 384 (Rear Drive Axle/Differential 8.8-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.
    CAUTION: Reinstall the differential pinion shaft (4211) and the bolt in the differential case (4204) after removing the axle shafts.
  1. Remove the axle shafts (4234). For additional information, refer to AXLE SHAFT .
  2. Wipe the lubricant from the internal working parts and inspect the parts for wear and damage.
  3. Rotate the differential assembly to check for roughness indicating bearing/gear damage.
    Fig 1: Rotating Differential Assembly
    G03434496Courtesy of FORD MOTOR CO.
    4. NOTE: There is a space between the anti-lock speed sensor ring (4B409) and the differential ring gear for measuring the differential ring gear backface runout.
    Fig 2: Measuring Ring Gear Backface Runout
    G03434497Courtesy of FORD MOTOR CO.
  4. Using a suitable dial indicator and the special tool, measure and note the differential ring gear backface runout.
    5. CAUTION: Mark the position of the bearing caps, as the arrows may not be visible. Always install the bearing caps in their identical locations and positions.
    Fig 3: Removing Bearing Caps
    G03434498Courtesy of FORD MOTOR CO.
  5. Remove the bearing caps.
    1. Remove the bolts.
    2. Remove the bearing caps.
    6. WARNING: Do not allow the differential assembly to fall.
    CAUTION: Place a wood block between the pry bar and the differential housing (4141) to protect the machined surface from damage.
    Fig 4: Removing Differential Assembly From Differential Housing
    G03434499Courtesy of FORD MOTOR CO.
  6. Using a pry bar and a wood block, remove the differential assembly from the differential housing.
  7. Remove the bolts.
    Fig 5: Removing Ring Gear Bolts
    G03434500Courtesy of FORD MOTOR CO.
    8. CAUTION: Do not damage the differential ring gear bolt hole threads.
    CAUTION: If removing the anti-lock speed sensor ring, discard it, and install a new antilock speed sensor ring during installation.
    Fig 6: Removing Ring Gear
    G03434501Courtesy of FORD MOTOR CO.
  8. Insert a punch in the bolt holes, and drive off the differential ring gear and, if necessary, the anti-lock speed sensor ring.
  9. If the differential ring gear backface runout measurement, taken at the beginning of this procedure, did not exceed the specification, proceed to the appropriate procedure as necessary: DIFFERENTIAL CASE AND RING GEAR - CONVENTIONAL  or DIFFERENTIAL CASE AND RING GEAR - TRACTION-LOK  in this section, or to Installation in this procedure. If the differential ring gear backface runout measurement, taken at the beginning of this procedure, exceeded the specification, the cause may be a warped differential ring gear, differential case/differential bearing damage. Proceed as follows to verify the cause of the excessive runout.
  10. Position the differential assembly, including the differential bearing cups (4222) and differential bearing shims (4067), in the differential housing. Install the bearing caps and the bolts.
    Fig 7: Installing Bearing Caps & Bolts
    G03434502Courtesy of FORD MOTOR CO.
  11. Position the special tool.
    1. Rotate the differential case to verify that the differential bearings (4221) have seated correctly.
    2. Position the special tool.
    Fig 8: Positioning Special Tool
    G03434503Courtesy of FORD MOTOR CO.
  12. Measure and note the differential case runout.
    • If the runout does not exceed the specification, install a new differential ring gear and pinion. For additional information, refer to DRIVE PINION  and to INSTALLATION .
    • If the runout exceeds the specification, the differential ring gear is true and the concern is due to either differential case/differential bearing damage. Proceed as follows.
    Fig 9: Measuring Differential Case Runout
    G03434504Courtesy of FORD MOTOR CO.
  13. Using the special tools, remove the differential bearings.
    Fig 10: Removing Differential Bearings
    G03434505Courtesy of FORD MOTOR CO.
  14. Using the special tool, install the new differential bearings.
    Fig 11: Installing Differential Bearings
    G03434506Courtesy of FORD MOTOR CO.
  15. Position the differential assembly, including the differential bearing cups and differential bearing shims in the differential housing. Tighten bearing caps to specification.
    Fig 12: Installing Bearing Caps & Bolts
    G03434507Courtesy of FORD MOTOR CO.
  16. Position the special tool.
    1. Rotate the differential case to verify that the differential bearings have seated correctly.
    2. Position the special tool.
    Fig 13: Positioning Special Tool
    G03434508Courtesy of FORD MOTOR CO.
  17. Measure the differential case runout.
    Fig 14: Measuring Differential Case Runout
    G03434509Courtesy of FORD MOTOR CO.
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