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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 777 (Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear) >> In-Vehicle Repair >> Differential Case >> Removal and Installation

Removal and Installation

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    CAUTION: Reinstall the differential pinion shaft and the bolt in the differential case after removing the axle shafts.
  1. Remove the axle shafts. For additional information, refer to AXLE SHAFT .
  2. Wipe the lubricant from the internal working parts and inspect the parts for wear and damage.
  3. Rotate the differential assembly to check for roughness indicating bearing or gear damage.
    Fig 1: Rotating Differential Carrier
    G03878557Courtesy of FORD MOTOR CO.
  4. Using a suitable dial indicator and the special tool, measure and record the differential ring gear backlash at four evenly spaced sections of the ring gear.
    Fig 2: Measuring Differential Ring Gear Backlash
    G03884037Courtesy of FORD MOTOR CO.
    5. CAUTION: Mark the position of the bearing caps, as the arrows may not be visible. Always install the bearing caps in their identical locations and positions.
  5. Remove the bearing caps.
    1. Remove the bolts.
    2. Remove the bearing caps.
      Fig 3: Removing Bearing Caps
      G03884038Courtesy of FORD MOTOR CO.
    6. WARNING: Do not allow the differential assembly to fall.
    CAUTION: Place a wood block between the pry bar and the differential housing to protect the machined surface.
    Fig 4: Removing Differential Assembly From Differential Housing
    G03884039Courtesy of FORD MOTOR CO.
  6. Using a pry bar and a wood block, remove the differential assembly from the differential housing.
  7. Remove the bolts.
    Fig 5: Removing Bolts
    G03971569Courtesy of FORD MOTOR CO.
    8. CAUTION: Do not damage the differential ring gear bolt hole threads.
    CAUTION: If removing the anti-lock speed sensor ring, discard it, and install a new anti-lock speed sensor ring during installation.
    Fig 6: Inserting Punch In Bolt Holes
    G03884041Courtesy of FORD MOTOR CO.
  8. Insert a punch in the bolt holes, and drive off the differential ring gear and, if necessary, the anti-lock speed sensor ring.
  9. If the differential ring gear backlash variation between teeth measurement, taken at the beginning of this procedure, did not exceed the specification, proceed to the appropriate procedure as necessary: DIFFERENTIAL CASE AND RING GEAR - Conventional DIFFERENTIAL CASE AND RING GEAR - TRACTION-LOK® . If the differential ring gear backlash variation between teeth measurement, taken at the beginning of this procedure, exceeded the specification, the cause may be a warped differential ring gear, differential case or differential bearing damage. Proceed as follows to verify the cause of the excessive variation.
  10. Position the differential assembly, including the differential bearing cups and differential bearing shims, in the differential housing. Install the bearing caps and the bolts.
    Fig 7: Installing Bearing Caps And Bolts
    G03884042Courtesy of FORD MOTOR CO.
  11. Position the special tool.
    1. Rotate the differential case to verify that the differential bearings have seated correctly.
    2. Position the special tool.
      Fig 8: Rotating Differential Case To Verify Differential Bearings
      G03878546Courtesy of FORD MOTOR CO.
  12. Measure and note the differential case runout.
    • If the runout does not exceed the specification, install a new differential ring gear and pinion. For additional information, refer to DRIVE PINION .
    • If the runout exceeds the specification, the differential ring gear is true and the concern is due to either differential case or differential bearing damage. Proceed as follows.
      Fig 9: Measuring Differential Case Runout
      G03912582Courtesy of FORD MOTOR CO.
  13. Using the special tools, remove the differential bearings.
    Fig 10: Removing Differential Bearings
    G03878548Courtesy of FORD MOTOR CO.
  14. Using the special tool, install the new differential bearings.
    Fig 11: Installing New Differential Bearings
    G03878549Courtesy of FORD MOTOR CO.
  15. Position the differential assembly, including the differential bearing cups and differential bearing shims in the differential housing. Tighten bearing caps to specification.
    Fig 12: Tightening Bearing Caps To Specification
    G03884042Courtesy of FORD MOTOR CO.
  16. Position the special tool.
    1. Rotate the differential case to verify that the differential bearings have seated correctly.
    2. Position the special tool.
      Fig 13: Rotating Differential Case To Verify Differential Bearings
      G03878546Courtesy of FORD MOTOR CO.
  17. Measure the differential case runout.
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