Differential Ring and Pinion: 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.
- Tag the outboard shims for location, LH and RH.
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 Tool
  Courtesy of FORD MOTOR CO.

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

Place the differential carrier in a vise.

NOTE: Whenever removing the differential ring gear bolts, always install new grade 9 differential ring gear bolts.

Fig 2: Removing Differential Ring Gear Bolts

Courtesy of FORD MOTOR CO.

Remove the differential ring gear bolts. Leave 4 differential ring gear bolts loosely assembled, 90 degrees apart.
Tap each differential ring gear bolt head alternately with a rawhide or plastic hammer to loosen the differential ring gear. Remove the differential ring gear bolts and the differential ring gear.
- Discard the differential ring gear bolts.
  
  Fig 3: Discarding Differential Ring Gear Bolts
  Courtesy of FORD MOTOR CO.
If necessary, remove and discard the anti-lock speed sensor ring with a soft-faced hammer.

Fig 4: Removing Anti-Lock Speed Sensor Ring With Soft-Faced Hammer
Courtesy of FORD MOTOR CO.
To maintain driveline balance, index-mark the driveshaft flange and the pinion flange.

Fig 5: Identifying Index-Mark Driveshaft Flange And Pinion Flange
Courtesy of FORD MOTOR CO.
Remove the 4 bolts.

Fig 6: Removing Bolts
Courtesy of FORD MOTOR CO.

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

Fig 7: Disconnecting Driveshaft Flange From Pinion Flange Using Suitable Tool

Courtesy of FORD MOTOR CO.

Using a suitable tool as shown, disconnect the driveshaft flange from the pinion flange and support the driveshaft using mechanic's wire.
Use the special tool to prevent the flange from turning while removing the lock nut and washer.

Fig 8: Removing Lock Nut And Washer Using Special Tool
Courtesy of FORD MOTOR CO.
Using the special tool, remove the pinion flange.

Fig 9: Removing Pinion Flange
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 10: Removing Drive Pinion 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 tools, remove and discard the drive pinion seal.

Fig 11: Removing Drive Pinion Seal Using Special Tool
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 12: 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 13: Removing Inner Pinion Bearing Cup Using Special Tools
Courtesy of FORD MOTOR CO.