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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 642 (Rear Drive Axle/Differential - DANA S135 -- F450-F550 Super Duty) >> Disassembly And Assembly >> Differential Case and Ring Gear >> Disassembly

Differential Case and Ring Gear: Disassembly

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.
  1. Mount the carrier housing in a suitable repair stand.
    Fig 1: Mounting Carrier Housing In Suitable Repair Stand
    G02769153Courtesy of FORD MOTOR CO.
    2. CAUTION: If reusing the differential ring gear and pinion, measure and record the backlash before disassembly. Assembling the differential ring gear and pinion to the recorded backlash will match the established wear patterns. Hand rolled patterns will cover less area than the established patterns.
  2. Measure and record the differential ring gear and pinion backlash.
    • Check the backlash in four equally spaced positions around the differential ring gear.
    • The tooth contact pattern can move only by adjusting backlash. The tooth contact pattern can move only in the direction of heel-to-toe, and toe-to-heel. Depth of the tooth contact pattern is not adjustable. Contact Spicer Service at 1-800-666-8688 for assistance if you are unable to establish an acceptable tooth contact pattern within the limits of backlash.
      Fig 2: Measuring And Record Differential Ring Gear And Pinion Backlash
      G02769154Courtesy of FORD MOTOR CO.
  3. Remove the rear anti-lock brake sensor.
    Fig 3: Removing Rear Anti-Lock Brake Sensor
    G02769155Courtesy of FORD MOTOR CO.
  4. Remove the adjusting ring locks.
    Fig 4: Removing Adjusting Ring Locks
    G02769156Courtesy of FORD MOTOR CO.
  5. Loosen, but do not remove, the four bolts.
    Fig 5: Loosening Bolts
    G02769157Courtesy of FORD MOTOR CO.
  6. Relieve the bearing preload.
    • Loosen each differential bearing adjusting ring.
    Fig 6: Loosening Each Differential Bearing Adjusting Ring
    G02769158Courtesy of FORD MOTOR CO.
    7. NOTE: The differential bearing caps are match marked at the factory.
    Fig 7: Removing Bolts
    G02769159Courtesy of FORD MOTOR CO.
  7. Remove the bolts, bearing caps and adjusting rings.
    8. CAUTION: Do not damage the differential ring gear and pinion.
    Fig 8: Lifting Differential Subassembly
    G02769160Courtesy of FORD MOTOR CO.
  8. Using the special tool, carefully lift the differential subassembly out of the carrier.
  9. Using the special tool, and a suitable puller, remove the differential side bearings if worn or damaged.
    Fig 9: Removing Differential Side Bearings
    G02769161Courtesy of FORD MOTOR CO.
  10. The Truetrac® differential assembly is non-repairable. Discard the entire assembly if it is worn or damaged.
    Fig 10: Discarding Differential Assembly
    G02769162Courtesy of FORD MOTOR CO.
  11. On the conventional differential assembly, separate the differential case halves.
    1. Match mark the case halves.
    2. Remove the bolts.
    3. Separate the case halves.
    Fig 11: Separating Case Halves
    G02769163Courtesy of FORD MOTOR CO.
  12. On the conventional differential assembly, remove the gear assembly.
    1. Remove the thrust washer and differential side gear.
    2. Remove the differential cross shaft with the pinion mates and the thrust washers.
    3. Remove the differential side gear and thrust washer.
    Fig 12: Removing Differential Side Gear And Thrust Washer
    G02769164Courtesy of FORD MOTOR CO.
    13. CAUTION: Do not use a chisel to remove the rivet heads. This will damage the differential case.
    CAUTION: Use a soft hammer to strike the punch.
    Fig 13: Identifying Differential Ring Gear
    G02769165Courtesy of FORD MOTOR CO.
  13. If discarding the pinion or differential ring gear, carefully center punch each differential ring gear rivet.
  14. Drill the rivet heads to the depth shown using the specified size drill bit.
    Fig 14: Drilling Rivet Heads To Depth
    G02769166Courtesy of FORD MOTOR CO.
  15. Separate the differential ring gear from the case.
      CAUTION: Use a soft hammer to strike the punch.
    1. Drive out the remaining rivet portions with a rounded type punch.
    2. Separate the differential ring gear from the case.
      3. CAUTION: Discard the anti-lock speed sensor ring if separating it from the case half.
      Fig 15: Removing Anti-Lock Speed Sensor Ring
      G02769167Courtesy of FORD MOTOR CO.
    3. If necessary, remove the anti-lock speed sensor ring and discard it.
    16. CAUTION: Alkaline cleaning solutions will damage machine surfaces. Use only emulsion cleaners or petroleum based cleaning solvent.
    CAUTION: Use soft, clean, lintless towels to dry the components.
    CAUTION: Never spin-dry bearings with compressed air. This will damage the mating surfaces due to a lack of lubrication.
    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.
    NOTE: For Truetrac® differentials, submerge the entire differential assembly in a suitable solvent to wash away contaminants from within the housing.
  16. Clean and dry the components.
  17. Inspect the bearing surfaces for pitting, wear and overheating.
    Fig 16: Inspecting Bearing Surfaces For Pitting, Wear And Overheating
    G02769168Courtesy of FORD MOTOR CO.
  18. Inspect the following:
    • the differential case machine surfaces.
    • the differential ring gear mounting holes for deformities, such as egg shaping.
    • all surfaces for nicks and cracks.
      Fig 17: Identifying Differential Ring Gear
      G02769169Courtesy of FORD MOTOR CO.
  19. Inspect the thrust washers for scoring and cracking.
    Fig 18: Inspecting Thrust Washers For Scoring And Cracking
    G02769170Courtesy of FORD MOTOR CO.
    20. CAUTION: Discard all gears in sets if one or more sustains wear or damage.
    Fig 19: Inspecting Gears For Pitting, Scoring, Wear And Damage
    G02769171Courtesy of FORD MOTOR CO.
  20. Inspect the gears for pitting, scoring, wear and damage.
  21. Inspect the shafts for nicks and scores.
    Fig 20: Inspecting Shafts For Nicks And Scores
    G02769172Courtesy of FORD MOTOR CO.
  22. Refer to DRIVE PINION  if disassembly is necessary.
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