Differential Case and Ring Gear - Conventional: Disassembly

WARNING: This page is about a different car, the 2004 Ford RV Cutaway, 2004 Ford Econoline, 2004 Ford E450 Super Duty, and 2004 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Differential bearing shims are available in thicknesses of 0.762, 0.787, 0.813, 0.838, 0.864, 0.889, and 0.914 mm (0.030, 0.031, 0.032, 0.033, 0.034, 0.035, and 0.036 inch).

NOTE: If differential bearing shims are damaged, install new ones.

NOTE: Install new differential bearings whenever they are removed from the rear axle differential carrier.

Fig 1: Removing Differential Bearings

Courtesy of FORD MOTOR CO.

Using the special tools, remove the differential bearings.
- Wire the differential bearing shims, differential bearing cup, differential bearing and outboard selective spacer together. Note from which side they were removed (ring gear side or opposite side).

NOTE: Use a vise with brass jaws or wood blocks.

Place the differential case in a vise.

CAUTION: Do not damage the anti-lock speed sensor ring when removing the ring gear. If the anti-lock speed sensor ring is removed, a new one must be installed.

NOTE: Whenever removing the ring gear bolts, always install new bolts upon assembly. Use Grade 9 bolts for service replacement for all Dana rear axles.

Fig 2: Identifying Ring Gear

Courtesy of FORD MOTOR CO.

Remove the bolts on the ring gear. Leave four bolts loosely assembled, 90 degrees apart.
Tap each bolt head alternately with a rawhide or plastic hammer to loosen the ring gear. Remove the bolts and the ring gear.

Fig 3: Removing Ring Gear
Courtesy of FORD MOTOR CO.
If required, remove the anti-lock speed sensor ring with a soft-faced hammer. Discard the anti-lock speed sensor ring.

Fig 4: Removing Anti-Lock Speed Sensor Ring
Courtesy of FORD MOTOR CO.

NOTE: Use a vise with brass jaws or wood blocks.

Fig 5: Driving Out Differential Pinion Shaft Lock Pin

Courtesy of FORD MOTOR CO.

Place the differential case in a vise. Using a small drift, drive out the differential pinion shaft lock pin that secures the differential pinion shaft.
Using a drift, remove the differential pinion shaft.

Fig 6: Removing Differential Pinion Shaft
Courtesy of FORD MOTOR CO.
To remove the differential side gears and the differential pinion gears, rotate the differential side gears. The differential pinion gears will turn to the opening of the differential case.

Fig 7: Removing Differential Side Gears And Differential Pinion Gears
Courtesy of FORD MOTOR CO.
Remove the differential pinion gears and the differential pinion thrust washers behind the differential pinion gears.
Lift out the differential side gears and the differential side gear thrust washers.