Differential Ring and Pinion: 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.

Remove the differential carrier. Refer to DIFFERENTIAL CARRIER .
Remove the ring gear bolts.

Fig 1: 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 2: Inserting A Punch In Bolt Holes

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.
Position the special tool.

Fig 3: Positioning Special Tool
Courtesy of FORD MOTOR CO.
Using 2 wrenches, remove the differential bearing.
- Repeat the procedure for the other differential bearing.
  
  Fig 4: Removing Differential Bearing
  Courtesy of FORD MOTOR CO.
Using the special tool, install the new differential bearings on the differential case.

Fig 5: Installing New Differential Bearings On Differential Case
Courtesy of FORD MOTOR CO.
To maintain driveline balance, index-mark the driveshaft flange and the pinion flange.

Fig 6: Identifying Mark Driveshaft Flange And Pinion Flange
Courtesy of FORD MOTOR CO.
Remove the 4 bolts.

Fig 7: 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 8: Disconnecting Driveshaft Flange From Pinion Flange

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

Fig 10: Removing Pinion Flange
Courtesy of FORD MOTOR CO.
Force up on the metal flange of the rear axle drive pinion seal. Install gripping pliers to the seal flange and strike with a hammer until the rear axle drive pinion seal is removed.
- Remove the oil slinger and the outer pinion bearing.
  
  Fig 11: Removing Oil Slinger And Outer Pinion Bearing
  Courtesy of FORD MOTOR CO.
Install the special tool and, with a soft-faced hammer, drive the pinion out of the front bearing cone and remove it through the rear of the housing.

Fig 12: Installing Special Tool And, With A Soft-Faced Hammer
Courtesy of FORD MOTOR CO.

CAUTION: Do not nick the axle housing bore.

Fig 13: Removing Outer Pinion Bearing Cup

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 14: Removing Inner Pinion Bearing Cup
Courtesy of FORD MOTOR CO.