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Disassembly And Assembly: Axle: Disassembly

WARNING: This page is about a different car, the 2005 Ford Pickup, 2005 Ford F550 Super Duty, 2005 Ford F450 Super Duty, and 2005 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the front wheel hubs and the front axle shaft assemblies. For additional information, refer to WHEEL HUB .
  2. Remove the differential housing cover and drain the lubricant.
    • Position the differential housing to allow the lubricant to drain completely.
    • Clean the gasket material from the differential housing and the differential housing cover.
      Fig 1: Removing Differential Housing Cover And Draining Lubricant
      G03919239Courtesy of FORD MOTOR CO.
    3. NOTE: An inspection can find the cause of the concern and determine the resolution.
  3. Carry out the following inspection.
    • Remove all the lubricant from the internal parts and visually inspect the parts for wear and damage.
    • Rotate the gears to check for roughness, indicating damage to the bearings/gears.
    • Check the teeth of the ring gear and pinion for signs of scoring, wear, nicks and chips.
      Fig 2: Identifying Ring Gear And Pinion Gear Teeth For Inspection
      G03919271Courtesy of FORD MOTOR CO.
    4. CAUTION: The differential ring gear and pinion must be clean and dry to obtain an accurate reading.
  4. Using the special tools, measure the ring gear and pinion backlash at 3 equally spaced points. Record the reading.
    • The backlash tolerance must be within the specification and cannot very more than 0.05 mm (0.002 in) between points checked. A backlash variation or more than 0.05 mm (0.002 in) indicates gear/case runout.
      • Make corrections for high or low backlash during assembly by changing the differential bearing selective shim thickness.
        Fig 3: Checking Ring Gear And Pinion Backlash
        G03919171Courtesy of FORD MOTOR CO.
    5. CAUTION: Prior to removal, note the stamped mating letters positioning on the bearing caps and the differential housing for correct reassembly.
    Fig 4: Removing Bearing Caps
    G03919240Courtesy of FORD MOTOR CO.
  5. Remove the bearing caps.
    6. CAUTION: Install the C-clamp at the 12 and 6 o'clock positions to allow the horizontal spread of the housing.
    CAUTION: Do not spread the differential housing more than specified.
    NOTE: Use a C-clamp with a minimum 15 inch opening and a 16,250 lb. load limit.
  6. Using a C-clamp, spread the differential housing 0.38 mm (0.015 in).
    • Remove special tool 100-D002 after spreading the differential housing.
      Fig 5: Spreading Differential Housing Using C-Clamp
      G03919169Courtesy of FORD MOTOR CO.
    7. CAUTION: Do not damage the ring gear and pinion.
  7. Using 2 pry bars, remove the differential with the bearing cups.
    • Remove the C-clamp after removing the differential.
    • For differential disassembly, refer to DIFFERENTIAL CASE .
  8. Measure the pinion bearing torque preload. Record the reading.
    • Rotate the pinion with a Nm (lb-in) torque wrench. Record the torque necessary to maintain rotation of the pinion through several revolutions.
      Fig 6: Checking Pinion Bearing Torque Preload
      G03919085Courtesy of FORD MOTOR CO.
  9. Remove and discard the nut and washer.
    • Use the special tool to prevent the flange from turning while removing the nut.
      Fig 7: Removing Nut And Washer
      G03919131Courtesy of FORD MOTOR CO.
    10. NOTE: Index-mark the flange and the pinion shaft.
    Fig 8: Removing Flange
    G03919195Courtesy of FORD MOTOR CO.
  10. Using the special tool, remove the flange.
    11. CAUTION: Do not damage the pinion, the bearings or the cup.
  11. Remove the pinion.
    • Using a soft face hammer, tap the pinion through the outer bearing. Remove the pinion through the rear of the differential housing.
      Fig 9: Removing Pinion
      G03919196Courtesy of FORD MOTOR CO.
  12. Using the special tools, remove the pinion seal. Discard the seal.
    Fig 10: Removing Drive Pinion Seal
    G03883494Courtesy of FORD MOTOR CO.
  13. Remove the oil slinger and the differential pinion bearing.
    Fig 11: Removing Oil Slinger And Differential Pinion Bearing
    G03919135Courtesy of FORD MOTOR CO.
  14. Using the special tools, remove the outer pinion bearing cup, the inner pinion bearing cup, and the oil baffle.
    • Use special tool 205-D055 and 205-D051 to remove the inner pinion bearing cup.
    • Use special tool 205-D055 and 205-D054 to remove the outer pinion bearing cup.
      Fig 12: Removing Inner Pinion Bearing Cup
      G03883496Courtesy of FORD MOTOR CO.
  15. Drive the inner axle shaft oil seals out of the differential housing through the axle tubes. Discard the seals.
    Fig 13: Driving Inner Axle Shaft Oil Seals Out Of Differential Housing Through Axle Tubes
    G03919282Courtesy of FORD MOTOR CO.
  16. Remove and discard the collapsible spacer.
    Fig 14: Removing Collapsible Spacer
    G03919137Courtesy of FORD MOTOR CO.
  17. Using the special tool, remove the differential pinion bearing.
    Fig 15: Removing Differential Pinion Bearing
    G03919201Courtesy of FORD MOTOR CO.
    18. NOTE: Discard the drive pinion position shim if bent or nicked. Measure and record the shim thickness if discarding the shim.
  18. Remove the drive pinion position shim.
  19. Carry out the following inspection.
      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.
    • Thoroughly clean all parts, including the differential housing and inside of the differential case.
    • 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.
      • Inspect the flange lugs for damage. The end of the flange that contacts the bearing cone as well as the nut counterbore and the seal contact area must be smooth and free of nicks.
      • Verify that the differential and pinion bearing bores are smooth. Remove any nicks/burrs from the mounting surfaces of the differential housing.
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