Differential Case: Removal

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Raise and support the vehicle. Refer to JACKING & LIFTING .
Remove the differential housing cover.
1. Remove the 12 differential housing cover bolts and drain the lubricant from the rear axle housing.
2. Remove the differential housing cover.
  
  Fig 1: Removing Differential Housing Cover
  Courtesy of FORD MOTOR CO.
Remove the axle shafts. Refer to AXLE SHAFT .
Wipe the lubricant from the internal working parts and visually inspect the parts for wear or damage.
Rotate the differential case to see if there is any roughness which would indicate damaged bearings or gears.

Fig 2: Removing Axle Shafts
Courtesy of FORD MOTOR CO.

NOTE: There is a space between the anti-lock speed sensor ring and the ring gear for measuring ring gear backface runout.

Fig 3: Inspecting Ring Gear Backlash And Ring Gear Backface Runout

Courtesy of FORD MOTOR CO.

Positioning the special tool, inspect ring gear backlash and ring gear backface runout.

CAUTION: Mark the position of the bearing caps, as arrows may not be visible. The bearing caps must be installed in their identical locations and positions.

Loosen the differential case.
1. Remove the bearing cap bolts.
2. Remove the bearing caps.
  
  Fig 4: Removing Bearing Caps
  Courtesy of FORD MOTOR CO.

WARNING: Be careful not to allow the differential case to fall.

CAUTION: Place a wood block between the pry bar and the rear axle housing to protect the machined surface from damage.

Fig 5: Placing A Wood Block Between Pry Bar And Rear Axle Housing

Courtesy of FORD MOTOR CO.

Use the pry bar and the wood block to remove the differential case from the rear axle housing.
Remove the ring gear bolts.

Fig 6: Removing Ring Gear Bolts
Courtesy of FORD MOTOR CO.

CAUTION: Care should be taken not to damage the ring bolt hole threads.

NOTE: The anti-lock speed sensor ring cannot be reused once removed.

Fig 7: Removing Ring Gear

Courtesy of FORD MOTOR CO.

Insert a punch in the bolt holes. Drive off the ring gear and, if necessary, the anti-lock speed sensor ring.
Install the differential case without the ring gear.
1. Position the differential case assembly, including bearing clips and shims, in the housing.
2. Install the differential bearing caps.
3. Install the differential bearing cap bolts.
  - Tighten to 119 Nm (88 lb-ft).
    
    Fig 8: Installing Differential Bearing Caps
    Courtesy of FORD MOTOR CO.

NOTE: Rotate the differential case to make sure the differential bearings are correctly seated.

NOTE: If runout is within specification, install a new ring gear and pinion. If runout exceeds specification, the ring gear is true and the concern is due to either a damaged differential case or differential bearings. Inspect the differential bearings. If the differential bearings are not damaged, install a new differential case and new differential bearings.

Fig 9: Measuring Differential Case Runout By Rotating Differential Case

Courtesy of FORD MOTOR CO.

Measure the differential case runout by rotating the differential case.
Remove the differential case from the rear axle housing and prepare to remove the differential bearings.
- Assemble the special tools.
  
  Fig 10: Assembling Special Tools For Removing Differential Bearings
  Courtesy of FORD MOTOR CO.
Position the special tool.

Fig 11: Positioning Special Tool
Courtesy of FORD MOTOR CO.
Using 2 wrenches, remove the differential bearing.
- Repeat the procedure for the other differential bearing.
  
  Fig 12: Removing Differential Bearing
  Courtesy of FORD MOTOR CO.
Using the special tool, install the new differential bearings on the differential case.

Fig 13: Installing New Differential Bearings On Differential Case
Courtesy of FORD MOTOR CO.
Measure the differential case runout without the ring gear.
- Check the case runout again with the new differential bearings. If the runout is now within the specification shown, use the new differential bearings for assembly. If the runout is still excessive, a new differential case is damaged and must be installed.
  
  Fig 14: Checking Case Runout Again With New Differential Bearings
  Courtesy of FORD MOTOR CO.