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Axle Assembly: Disassembly

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  1. Remove the differential housing cover and drain the lubricant.
    • Clean the gasket material from the differential housing cover and the differential housing.
    2. NOTE: An inspection can find the cause of the concern and determine the resolution.
    Fig 1: Checking Differential Ring Gear And Pinion Teeth
    G01947973Courtesy of FORD MOTOR CO.
  2. Carry out the following before disassembly.
    • Remove all the lubricant from the internal parts of the differential assembly. Visually inspect the parts for wear and damage.
    • Rotate the differential assembly to check for any roughness, indicating damaged bearings or gears.
    • Check the differential ring gear and pinion teeth for signs of scoring, abnormal wear, nicks and chips.
    • Use a magnet to search for heavy metal particles indicating component damage.
    3. CAUTION: The differential ring gear and pinion must be clean and dry to obtain an accurate reading.
  3. Using the special tools, measure the differential ring gear and pinion backlash at three equally spaced points.
    • The backlash tolerance is 0.13-0.20 mm (0.005-0.008 inch) and cannot vary more than 0.05 mm (0.002 inch) between points checked. A backlash variation of more than 0.05 mm (0.002 inch) indicates gear/case runout.
      Fig 2: Measuring Differential Ring Gear And Pinion Backlash
      G01947974Courtesy of FORD MOTOR CO.
    • Make corrections for high or low backlash during assembly by changing the differential bearing selective shim thickness.
  4. Remove the axle shafts. For additional information, refer to WHEEL HUBS AND BEARINGS - FULL FLOATING AXLE or refer to AXLE SHAFT-SEMI-FLOATING AXLE .
    5. CAUTION: Note the positions of the mating letters stamped vertically and horizontally on the bearing caps and the differential housing before removing the bearing caps. Matching the letters is important at the time of assembly.
    Fig 3: Identifying Differential Case
    G01947975Courtesy of FORD MOTOR CO.
  5. To ease removal of the differential assembly, loosen the bolts, then pry the differential case, bearing cups and outboard spacers outward until they are loose in the differential housing.
  6. Remove the bolts and the bearing caps.
    7. CAUTION: Do not spread the differential housing more than specified.
    Fig 4: Removing Special Tool
    G01947976Courtesy of FORD MOTOR CO.
  7. Using the special tools, spread the differential housing to the specification. Remove special tool 100-D002 after spreading the housing.
    8. CAUTION: It will be necessary to use large pry bars to remove the differential assembly from the differential housing. Do not damage the differential ring rear when carrying out this step.
    CAUTION: Mark or tag the differential bearing cups, indicating from which side they were removed.
    Fig 5: Removing Differential Assembly With Bearing Cups
    G01947977Courtesy of FORD MOTOR CO.
  8. Remove the differential assembly with the bearing cups.
    • Remove the special tool after removing the differential assembly.
    • Inspect the differential bearing cups for deep scores, galling and spalling. Discard them if necessary.
    9. CAUTION: Mark or tag the outboard spacers indicating from which side they were removed.
    Fig 6: Inspecting Spacers For Nicks
    G01947978Courtesy of FORD MOTOR CO.
  9. Remove the outboard spacers.
    • Inspect the spacers for nicks, bending and grooved conditions. Discard them if necessary.
    10. CAUTION: Index-mark the pinion flange to the pinion shaft prior to removal.
    Fig 7: Removing Lock Nut And Washer With Special Tool
    G01947979Courtesy of FORD MOTOR CO.
  10. Use the special tool to prevent the flange from turning while removing the lock nut and washer.
  11. Using the special tool, remove the pinion flange.
    Fig 8: Removing Pinion Flange With Special Tool
    G01947980Courtesy of FORD MOTOR CO.
    12. NOTE: There are drive pinion bearing preload shims and, on Model 70 axles, a preload spacer on the spline-end of the pinion. These shims and spacer can stick to the pinion, the pinion bearing, or they can fall out of the differential housing. Collect and keep the shims and spacer for reassembly.
    Fig 9: Removing Pinion Of Pinion Bearing Cup
    G01947981Courtesy of FORD MOTOR CO.
  12. Using a soft-face hammer, tap the pinion out of the pinion bearing cup and remove it through the rear of the differential housing.
  13. Using the special tools, remove and discard the pinion seal.
    Fig 10: Removing Pinion Seal With Special Tool
    G01947982Courtesy of FORD MOTOR CO.
  14. Remove the oil slinger and the pinion bearing.
    15. CAUTION: Do not nick the differential housing bore.
    Fig 11: Removing Outer Pinion Bearing Cup
    G01947983Courtesy of FORD MOTOR CO.
  15. Using the special tools, remove the outer pinion bearing cup.
    • For Model 60/70 axles, use tools 205-D054 and 205-D055.
  16. Using the special tools, remove the inner pinion bearing cup.
    • For Model 60 axles, use tools 205-D051 and 205-D055.
    • For Model 70 axles, use tools 205-D052 and 205-D055.
    Fig 12: Removing Inner Pinion Bearing Cup
    G01947984Courtesy of FORD MOTOR CO.
  17. Using the special tool, remove the inner pinion bearing.
    Fig 13: Removing Inner Pinion Bearing
    G01947985Courtesy of FORD MOTOR CO.
    18. NOTE: Discard the drive pinion position shim if bent or nicked. If discarding the shim, measure and record the shim thickness.
  18. Remove the drive pinion position shim.
  19. Carry out the following after disassembling the axle:
    • Thoroughly clean all parts.
    • Inspect all parts for damage and wear.
    • Clean the inside of the differential case before assembly.
      • Thoroughly clean the differential housing if the gears have scores/chips in them.
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