LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 641 (Rear Drive Axle/Differential - DANA S110 -- F450-F550 Super Duty) >> In-Vehicle Repair >> Differential Carrier >> Removal

Differential Carrier: Removal

WARNING: This page is about a different car, the 2004 Ford F550 Super Duty and 2004 Ford F450 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: Do not use heat when disassembling a drive axle. To do so will destroy heat treat properties and weaken or distort axle components. Failure to follow these instructions may result in personal injury.
    CAUTION: Steam clean the axle prior to removal from the vehicle. Dirt is abrasive and will cause premature wear of otherwise usable parts.
  1. Steam clean the axle assembly.
  2. Set the parking brake.
    Fig 1: Identifying Parking Brake
    G02769007Courtesy of FORD MOTOR CO.
  3. Chock the wheels.
    Fig 2: Chocking Wheels
    G02769008Courtesy of FORD MOTOR CO.
  4. Drain the axle lubricant into a suitable container.
    • Remove the bottom two carrier bolts and drain the assembly.
      Fig 3: Removing Bottom Two Carrier Bolts And Drain Assembly
      G02769009Courtesy of FORD MOTOR CO.
  5. Disconnect the rear anti-lock brake sensor electrical connector, if equipped.
    Fig 4: Disconnecting Rear Anti-Lock Brake Sensor Electrical Connector
    G02769010Courtesy of FORD MOTOR CO.
  6. Index-mark and disconnect the driveshaft, and position it aside. Refer to DRIVESHAFT .
    Fig 5: Disconnecting Driveshaft
    G02769011Courtesy of FORD MOTOR CO.
  7. Loosen the pinion hex nut if drive pinion disassembly is necessary.
    Fig 6: Loosing Pinion Hex Nut Drive Pinion
    G02769012Courtesy of FORD MOTOR CO.
    8. WARNING: Do not strike the axle shaft flange directly with a steel hammer or sledge. This will crack and splinter the flange. Failure to follow these instructions may result in personal injury.
    CAUTION: Do not pry or chisel the axle shaft flange away from the hub. This will damage the sealing surface.
    Fig 7: Removing Axle Shafts
    G02769013Courtesy of FORD MOTOR CO.
  8. Remove the axle shafts. Refer to WHEEL HUBS & BEARINGS - FULL FLOATING AXLE - DANA .
  9. Remove all but the two top carrier-to-axle housing retaining bolts, noting the length and position of each bolt.
    • Discard the differential carrier housing bolts.
      Fig 8: Discarding Differential Carrier Housing
      G02769014Courtesy of FORD MOTOR CO.
    10. WARNING: Secure the carrier to the jack to prevent it from falling when removing it from the axle housing. Failure to follow these instructions may result in personal injury.
  10. Remove the carrier from the axle housing.
    1. Position a suitable jack under the carrier.
    2. Remove and discard the remaining retaining bolts.
    3. Use the slots to separate the carrier approximately 25.4-50.8 mm (1-2 inches) from the axle housing.
    4. Secure the carrier to a suitable jack, and remove the carrier from the axle housing.
      Fig 9: Removing Carrier From Axle Housing
      G02769015Courtesy of FORD MOTOR CO.
    11. CAUTION: Alkaline cleaning solutions will damage machine surfaces. Use only emulsion cleaners or petroleum based cleaning solvent.
    CAUTION: Use only soft, clean, lintless towels to dry the components.
    CAUTION: After drying, lightly coat the parts with rust inhibitor or clean lubricant to prevent damage from corrosion. Wrap all parts that are going to be in storage for a prolonged period in wax paper.
  11. Clean and dry the components as necessary.
  12. Inspect the gear set for pitting, scoring, wear and damage.
    Fig 10: Inspecting Gear Set For Pitting Scoring, Wear
    G02769016Courtesy of FORD MOTOR CO.
  13. Inspect the splines for wear, cracking and distortion from twisting.
    Fig 11: Inspecting Splines For Wear Cracking And Distortion From Twisting
    G02769017Courtesy of FORD MOTOR CO.
  14. Inspect the axle flange O-ring.
    Fig 12: Inspecting Axle Flange O-Ring
    G02769018Courtesy of FORD MOTOR CO.
  15. Clean the axle housing interior, the axle and carrier housing sealing surfaces, and the carrier mounting bolt hole threads. Inspect the housing for stripped and damaged threads and bending fatigue.
    Fig 13: Inspecting Housing For Stripped And Damaged Threads And Bending Fatigue
    G02769019Courtesy of FORD MOTOR CO.
  16. If carrier disassembly is necessary, refer to DIFFERENTIAL CASE AND RING GEAR .
scientia non olet · About LEMON Manuals