Differential Case: Removal

WARNING: This page is about a different car, the 2006 Mercury Grand Marquis and 2006 Ford Crown Victoria. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: If equipped with fire suppression system, depower the system. For important safety warnings and procedures, refer to FIRE SUPPRESSION SYSTEM .

Remove the axle shafts. For additional information, refer to AXLE SHAFT .
Wipe the lubricant from the internal working parts and inspect the parts for wear and damage.
Rotate the differential assembly to check for roughness indicating bearing/gear damage.
Using a suitable dial indicator and the special tool, measure and record the differential ring gear backlash between the teeth in 4 opposing places.

Fig 1: Measuring Differential Ring Gear Backlash
Courtesy of FORD MOTOR CO.

CAUTION: Mark the position of the differential bearing caps, as the arrows may not be visible. Always install the bearing caps in their identical locations and positions.

Remove the differential bearing caps.
1. Remove the bolts.
2. Remove the differential bearing caps.
  
  Fig 2: Removing Differential Bearing Caps
  Courtesy of FORD MOTOR CO.

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 from damage.

Fig 3: Removing Differential Carrier Assembly From Axle Housing

Courtesy of FORD MOTOR CO.

Using a pry bar and a wood block, remove the differential assembly from the differential housing.
Remove the differential ring gear bolts.

Fig 4: Removing Differential Ring Gear Bolts
Courtesy of FORD MOTOR CO.

CAUTION: Do not damage the differential ring gear bolt hole threads.

Fig 5: Removing Differential Ring Gear

Courtesy of FORD MOTOR CO.

Insert a punch in the bolt holes, and drive off the differential ring gear.
If the differential ring gear backlash variation between teeth measurement, taken at the beginning of this procedure, did not exceed the specification, proceed to INSTALLATION . 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 or differential case/differential bearing damage. Proceed as follows to verify the cause of the excessive backlash.

NOTE: Visually inspect the differential bearing cups and cones for discoloration indicating bearing overheating or failure.

Position the differential assembly, including the differential bearing cups and differential bearing shims as removed, in the differential housing. Install the differential bearing caps and the bolts.
- Tighten to 114 Nm (84 lb-ft).
  
  Fig 6: Identifying Differential Bearing Cap And Differential Bearing Cap Bolts
  Courtesy of FORD MOTOR CO.
Install the special tool.
1. Rotate the differential case to verify that the differential bearings have seated correctly.
2. Position the special tool.
  - Make sure there is no differential case endplay.
    
    Fig 7: Installing Special Tool
    Courtesy of FORD MOTOR CO.
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 DIFFERENTIAL RING AND PINION .
- If the runout exceeds the specification, the concern is due to differential case/differential bearing damage. Install a new differential case. For additional information, refer to DIFFERENTIAL CASE AND RING GEAR - CONVENTIONAL or DIFFERENTIAL CASE AND RING GEAR - TRACTION-LOK® .
  
  Fig 8: Measuring Differential Case Runout
  Courtesy of FORD MOTOR CO.
Using the special tools, remove the differential bearings.

Fig 9: Removing Differential Bearing Using Special Tools
Courtesy of FORD MOTOR CO.