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Differential Bearings - Front Axle: Removal

WARNING: This page is about a different car, the 2004 Mercury Mountaineer and 2004 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the axle assembly. For additional information, refer to FRONT AXLE ASSEMBLY .
  2. Drain the front axle assembly.
    1. Remove the differential housing cover bolts.
    2. Remove the differential cover.
    Fig 1: Removing Differential Cover
    G03190368Courtesy of FORD MOTOR CO.
  3. Install the special tools on the differential housing.
    Fig 2: Installing Special Tools On Differential Housing
    G03190369Courtesy of FORD MOTOR CO.
  4. Install the special tool fixture on the adapters and mount on a bench.
    Fig 3: Installing Special Tool
    G03190370Courtesy of FORD MOTOR CO.
  5. Remove the differential bearing caps.
    1. Remove the differential bearing cap bolts.
    2. Remove and identify the differential bearing caps.
    Fig 4: Removing And Identifying Differential Bearing Caps
    G03190371Courtesy of FORD MOTOR CO.
  6. Install the special tool.
    Fig 5: Installing Special Tool
    G03190372Courtesy of FORD MOTOR CO.
  7. Install the special tools.
    Fig 6: Installing Special Tool
    G03190373Courtesy of FORD MOTOR CO.
    8. CAUTION: Overspreading can damage the differential housing.
    Fig 7: Spreading Differential Housing To Specification
    G03190374Courtesy of FORD MOTOR CO.
  8. Spread the differential housing to the specification.
    1. Adjust the special tool to zero.
    2. Tighten the differential carrier spreader screw.
    3. Remove the dial indicator.
    9. CAUTION: Use wood blocks to avoid damaging the differential housing.
    Fig 8: Removing Differential Assembly
    G03190375Courtesy of FORD MOTOR CO.
  9. Remove the differential assembly from the housing.
    1. Position the wood blocks.
    2. Push downward on the pry bars.
    3. Remove the differential assembly.
    4. Remove the special tool.
  10. Remove the differential ring gear bolts and the differential ring gear.
    • Use a drift punch to separate the differential ring gear from the differential case.
    Fig 9: Removing Differential Ring Gear Bolts
    G03190376Courtesy of FORD MOTOR CO.
  11. Assemble the special tools.
    Fig 10: Assembling Special Tools
    G03190377Courtesy of FORD MOTOR CO.
  12. Position the special tool on the differential bearing.
    Fig 11: Positioning Special Tool On Differential Bearing
    G03190378Courtesy of FORD MOTOR CO.
  13. Using the special tool, remove the differential bearings.
    Fig 12: Removing Differential Bearings Using Special Tool
    G03190264Courtesy of FORD MOTOR CO.
  14. Using the special tool to hold the pinion flange, remove and discard the pinion nut and washer.
    Fig 13: Holding Pinion Flange And Removing Nut Using Special Tool
    G03190380Courtesy of FORD MOTOR CO.
  15. Using the special tool, remove the pinion flange.
    Fig 14: Removing Pinion Flange Using Special Tool
    G03190381Courtesy of FORD MOTOR CO.
    16. WARNING: The gear teeth have sharp edges. Handle the gear with care to avoid personal injury.
    Fig 15: Removing Pinion From Differential Housing
    G03190382Courtesy of FORD MOTOR CO.
  16. Using a soft-face hammer, remove the pinion from the differential housing.
    1. Hold the pinion inside the differential housing.
    2. Use a soft-face hammer to remove the pinion from the outer pinion bearing.
  17. Using the special tool, remove the drive pinion oil seal.
    Fig 16: Removing Drive Pinion Oil Seal Using Special Tool
    G03190383Courtesy of FORD MOTOR CO.
  18. Remove the front axle drive pinion shaft oil slinger and the outer pinion bearing.
    Fig 17: Removing Outer Pinion Bearing
    G03190384Courtesy of FORD MOTOR CO.
  19. Remove the inner pinion bearing.
    1. Position the special tool under the bearing.
    2. Using a shop press, remove the inner pinion bearing.
    Fig 18: Removing Inner Pinion Bearing
    G03190385Courtesy of FORD MOTOR CO.
  20. Remove the drive pinion position shim.
    • Measure and record the thickness of the pinion position shim for reference during installation.
    Fig 19: Removing Drive Pinion Position Shim
    G03190386Courtesy of FORD MOTOR CO.
    21. NOTE: To prevent it from becoming misaligned in the bore, remove the inner pinion bearing cup by tapping alternately on each side of the inner pinion bearing cup with a brass drift.
    Fig 20: Removing Inner Pinion Bearing Cup
    G03190387Courtesy of FORD MOTOR CO.
  21. Remove the inner pinion bearing cup.
    22. NOTE: To prevent it from becoming misaligned in the bore, remove the outer pinion bearing cup by tapping alternately on each side of the outer pinion bearing cup with a brass drift.
    Fig 21: Removing Outer Pinion Bearing Cup
    G03190388Courtesy of FORD MOTOR CO.
  22. Remove the outer pinion bearing cup.
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