Differential Carrier: 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.

With the vehicle in NEUTRAL, position it on a hoist.
Remove the 10 differential housing cover bolts and the differential housing cover.
- 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: Identifying Mating Letters

Courtesy of FORD MOTOR CO.

Remove the 4 bolts and the 2 bearing caps.

CAUTION: Do not spread the differential housing more than specified or damage to the housing may occur.

Fig 2: Special Tools With Torque Specifications

Courtesy of FORD MOTOR CO.

Using the special tools, spread the differential housing.

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

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

Fig 3: Removing Differential Assembly With Bearing Cups

Courtesy of FORD MOTOR CO.

Remove the differential assembly with the bearing cups.

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

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