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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 646 (Front Drive Axle/Differential -- Excursion & F250-F550 Super Duty) >> Disassembly And Assembly >> Differential Case >> Disassembly

Differential Case: Disassembly

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION: Do not reuse the bearings after removing them from the differential case.
  1. Remove the differential bearings and the shims.
    1. Place the differential into a vise with soft jaws.
    2. Using the special tool, remove the differential bearing.
      3. CAUTION: Discard any damaged shims at time of assembly.
    3. Remove the differential bearing shims.
      • Wire the shims, the bearing cone and the cup together. Identify from which side they were removed.
        • Repeat the procedure for the opposite side.
          Fig 1: Removing Differential Bearing Using Special Tools
          G02769892Courtesy of FORD MOTOR CO.
          Fig 2: Removing Differential Bearing Shims
          G02769893Courtesy of FORD MOTOR CO.
    2. CAUTION: Discard the bolts after removing them from the differential case.
    CAUTION: Place shop towels under the ring gear to prevent ring gear damage.
  2. Remove the ring gear.
    1. Place the differential case into a vise with soft jaws.
    2. Remove and discard all but 4 of the bolts. Leave 4 loosely assembled bolts spaced apart from each other.
    3. Tap each bolt head alternately with a soft face hammer to loosen the ring gear. Remove the bolts and the ring gear. Discard the bolts.
      Fig 3: Removing Ring Gear
      G02769894Courtesy of FORD MOTOR CO.
  3. Using a hammer and a small drift, drive out the differential pinion shaft lock pin.
    Fig 4: Removing Differential Pinion Shaft Lock Pin Using Hammer And Small Drift
    G02769895Courtesy of FORD MOTOR CO.
  4. Remove the differential pinion shaft.
    Fig 5: Removing Differential Pinion Shaft
    G02769896Courtesy of FORD MOTOR CO.
  5. Remove the differential pinion gears and thrust washers and the differential side gears and thrust washers.
    Fig 6: Removing Differential Side Gears And Thrust Washers
    G02769897Courtesy of FORD MOTOR CO.
    6. CAUTION: Always use new solvent when cleaning the bearings.
    CAUTION: Do not spin dry the bearings with compressed air.
    CAUTION: Oil the bearings immediately, to prevent rusting.
    CAUTION: If upon inspection, any component has score marks/chips, thoroughly clean the differential housing.
  6. Carry out the following inspection.
    • Thoroughly clean all parts.
    • Inspect all parts for damage.
      • Discard the complete differential if excessive wear is visible on all parts.
      • Discard both differential pinion gears and both differential side gears if any one of these gears are worn/damaged.
      • Verify that the differential bearing bores are smooth. Remove any nicks/burrs from the mounting surfaces of the differential housing.
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