Differential Ring And Pinion: Disassembly

WARNING: This page is about a different car, the 2005 Lincoln LS. However, it is still accessible from the selected car via links, so may be relevant.

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to NOISE, VIBRATION & HARSHNESS .
Remove the rear axle assembly. For additional information, refer to AXLE ASSEMBLY in this article .
Drain the axle.

Fig 1: Identifying Axle Assembly Components
Courtesy of FORD MOTOR CO.

CAUTION: The machined surfaces on the differential housing and the differential housing cover must be clean and free of oil before applying the new Silicone Gasket and Sealant F7AZ-19554-EA meeting Ford specification WSE-M4G323-A4. Cover the inside of the axle before cleaning the machined surface to prevent contamination.

Remove the differential housing cover.
Mount the differential assembly in the special tool.

Fig 2: Mounting Differential Assembly In Special Tool
Courtesy of FORD MOTOR CO.

CAUTION: After removing the differential drive pinion nut, discard it. Use a new differential drive pinion nut for installation.

Fig 3: Holding Rear Axle Pinion Flange Using Special Tool

Courtesy of FORD MOTOR CO.

Use the special tool to hold the rear axle pinion flange while removing the differential drive pinion nut.
Using the special tool, remove the rear axle pinion flange.

Fig 4: Removing Rear Axle Pinion Flange
Courtesy of FORD MOTOR CO.
Use a screwdriver to force up the metal flange of the rear pinion oil seal. Install gripping pliers and strike with a hammer to remove the rear pinion oil seal.

Fig 5: Removing Drive Pinion Seal
Courtesy of FORD MOTOR CO.
Remove the rear pinion oil seal slinger, outer pinion bearing and the drive pinion collapsible spacer.
Force up the metal flange on the halfshaft housing seals.

Fig 6: Forcing Up Metal Flange On Halfshaft Housing Seals
Courtesy of FORD MOTOR CO.
Install gripping pliers and strike with a hammer to remove the halfshaft housing seals from the housing.

Fig 7: Removing Halfshaft Housing Seals From Housing
Courtesy of FORD MOTOR CO.
Index mark the differential bearing cap, then remove the differential bearing cap bolts and bearing cap.

Fig 8: Marking Index Mark On Differential Bearing Cap
Courtesy of FORD MOTOR CO.
Remove the selective snap ring, differential bearing shim and the differential bearing cups.
Remove the differential case assembly.
Remove the differential ring gear bolts then the differential ring gear.

Fig 9: Identifying Differential Ring Gear Bolts
Courtesy of FORD MOTOR CO.
Using the special tools, remove the differential bearings.

Fig 10: Removing Differential Bearings
Courtesy of FORD MOTOR CO.
Remove the differential pinion gear.
Using a drift punch and a hammer, remove the inner pinion bearing cup.
Using a drift punch and a hammer, remove the outer pinion bearing cup.

Fig 11: Removing Outer Pinion Bearing Cup
Courtesy of FORD MOTOR CO.