Differential Case: Removal

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.

Remove the axle shafts. 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 to see if there is any roughness to indicate damaged bearings or gears.

Fig 1: Checking Roughness To Indicate Damaged Bearings Or Gears
Courtesy of FORD MOTOR CO.
Position the special tool, and record ring gear backlash at four evenly spaced sections of the ring gear.

Fig 2: Measuring Ring Gear Backlash
Courtesy of FORD MOTOR CO.

CAUTION: Mark the position of the bearing caps because the arrows may not be visible. The bearing caps must be installed in their identical locations and positions.

Fig 3: Removing Bearing Caps Bolts

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: Fabricating Two Differential Case Retaining Straps From Metal Stock
Courtesy of FORD MOTOR CO.

WARNING: Be careful to not allow the differential case to fall.

CAUTION: Place a wood block between the pry bar and the rear axle housing to protect the machined surface from damage.

Fig 5: Removing Differential Case From Rear Axle Housing

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 to not damage the ring gear bolt hole thread.

NOTE: The anti-lock speed sensor ring cannot be reused once removed.

Fig 7: Driving Off 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 cups and shims, in the carrier.
2. Install the differential bearing caps.
3. Install the differential bearing cap bolts.
Fig 8: Installing Differential Bearing Caps Bolts
Courtesy of FORD MOTOR CO.
Position the special tool.
1. Rotate the differential case to make sure the differential bearings are correctly seated.
2. Install the special tool.
Fig 9: Positioning 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 Without Ring Gear

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
Courtesy of FORD MOTOR CO.
Using the special tool, install the new differential bearings on the differential case.

Fig 12: Installing New Differential Bearings On Differential Case
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 within specification, 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 Without Ring Gear
Courtesy of FORD MOTOR CO.