Differential Case: 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.

Raise the vehicle on a hoist or raise the rear end of the vehicle with a jack. Install safety stands under the frame rails and lower the jack or hoist far enough to allow the rear axle to drop into the rebound position for working clearance.
Remove the differential housing cover and drain the lubricant from the rear axle.
- Clean the gasket material from the differential housing cover and the differential housing.
Remove the axle shafts. Refer to WHEEL HUBS & BEARINGS - FULL FLOATING AXLE - DANA .

CAUTION: Note the positions of the mating letters stamped vertically and horizontally on the bearing caps and the differential housing before removing the bearing caps.

Fig 1: Removing Bearing Cups

Courtesy of FORD MOTOR CO.

Remove the bolts and the bearing caps.

CAUTION: Do not spread the differential housing more than specified.

Fig 2: Spread The Differential Housing Using Special Tools

Courtesy of FORD MOTOR CO.

Using the special tools, spread the differential housing to the specifications, then remove the Dial Indicator Gauge with Holding Fixture.

CAUTION: It will be necessary to use large pry bars to remove the differential assembly from the differential housing. Do not damage the differential ring rear when carrying out this step.

CAUTION: Mark or tag the differential bearing cups, indicating from which side they were removed.

Remove the differential assembly with the bearing cups.
- Remove the special tool after removing the differential assembly.
- Inspect the differential bearing CUDS for deep scores, galling and spelling.
  
  Fig 3: Removing Differential Assembly With Bearing Cups
  Courtesy of FORD MOTOR CO.

CAUTION: Mark or tag the outboard spacers indicating from which side they were removed.

Remove the outboard spacers.
- Inspect the spacers for nicks, bending or grooved conditions.
  
  Fig 4: Removing Outboard Spacers
  Courtesy of FORD MOTOR CO.

NOTE: Differential bearings 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 in).

NOTE: If damaged, install new differential bearing shims.

NOTE: Install new differential bearings and cups if removing the bearings from the differential case.

Using the special tools, remove the differential bearings.
- Tag the selective outboard spacers to identify the side from which they were removed. If the differential bearings are removed, add the bearing shims to the spacers for the appropriate side.
  
  Fig 5: Removing Differential Bearings Using Special Tool
  Courtesy of FORD MOTOR CO.

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 differential ring gear. If removing the anti-lock speed sensor ring, discard it and install a new one.

NOTE: Always use new bolts upon reassembly.

Fig 6: Removing Ring Gear Bolts

Courtesy of FORD MOTOR CO.

Remove the ring gear bolts. Leave 4 bolts loosely assembled, 90 degrees apart.
Tap each bolt head alternately with a rawhide or plastic hammer to loosen the differential ring gear. Remove and discard the bolts. Remove the differential ring gear.

Fig 7: Discarding Differential Ring Gear Bolts
Courtesy of FORD MOTOR CO.
If necessary, remove the anti-lock speed sensor ring with a soft-faced hammer. Discard the anti-lock sensor ring.

Fig 8: Removing Anti-Lock Speed Sensor Ring Using Soft-Faced Hammer
Courtesy of FORD MOTOR CO.