Differential Bearings: Removal

WARNING: This page is about a different car, the 2004 Ford Pickup and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Remove the differential carrier assembly.
Using the special tools, remove the differential bearings.
- Place the left and right differential bearing shims with the respective outboard spacers.
  
  Fig 1: Removing Differential Bearings Using Special Tools
  Courtesy of FORD MOTOR CO.
To maintain driveline balance, index-mark the driveshaft flange yoke and the pinion flange.

Fig 2: Identifying Index-Mark Driveshaft Flange Yoke And Pinion Flange
Courtesy of FORD MOTOR CO.
Remove the 4 bolts.

Fig 3: Removing Bolts
Courtesy of FORD MOTOR CO.

CAUTION: The driveshaft flange yoke fits tightly on the pinion flange yoke. Never hammer on the driveshaft or any of its components to disconnect the yoke from the flange. Pry only in the area shown, with a suitable tool, to disconnect the yoke from the flange.

Fig 4: Disconnecting Driveshaft Flange Yoke From Pinion Flange Using Suitable Tool

Courtesy of FORD MOTOR CO.

Using a suitable tool as shown, disconnect the driveshaft flange yoke from the pinion flange and support the driveshaft using mechanic's wire.

CAUTION: Index-mark the pinion flange to the pinion shaft prior to removal.

Fig 5: Removing Washer And Locknut Using Special Tool

Courtesy of FORD MOTOR CO.

Use the special tool to prevent the flange from turning while removing the lock nut and washer.
Using the special tool, remove the pinion flange.

Fig 6: Removing Pinion Flange Using Special Tool
Courtesy of FORD MOTOR CO.

NOTE: There are drive pinion bearing preload shims on the splined-end of the pinion shaft. These drive pinion bearing preload shims can stick to the pinion shaft, the pinion bearing or they can fall out of the axle housing. Collect and keep the drive pinion bearing preload shims for reassembly.

Fig 7: Removing Pinion From Pinion Bearing Using Special Tool

Courtesy of FORD MOTOR CO.

Using the special tool, drive the pinion from the outer the pinion bearing and remove it through the rear of the axle housing.
Using the special tool and a suitable press, remove the inner pinion bearing.

Fig 8: Removing Inner Pinion Bearing Using Special Tool And Press
Courtesy of FORD MOTOR CO.
Using the special tools, remove and discard the drive pinion seal.

Fig 9: Removing Drive Pinion Seal Using Special Tools
Courtesy of FORD MOTOR CO.
Remove the drive pinion oil slinger, the outer drive pinion bearing and the pinion preload adjustment shims.

CAUTION: Do not nick the axle housing bore.

Fig 10: Removing Outer Pinion Bearing Cup Using Special Tools

Courtesy of FORD MOTOR CO.

Using the special tools, remove the outer pinion bearing cup.
Using the special tools, remove the inner pinion bearing cup.

Fig 11: Removing Inner Pinion Bearing Cup Using Special Tools
Courtesy of FORD MOTOR CO.