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Home >> Ford >> 2000 >> Taurus LX, 3.0 2, AX4N >> Repair and Diagnosis >> External Pages >> Different car >> Section 938 (Front Drive Axle/Differential -- F250-F550 Super Duty) >> Disassembly And Assembly >> Axle >> Disassembly

Disassembly And Assembly: Axle: Disassembly

WARNING: This page is about a different car, the 2007 Ford Pickup, 2007 Ford F550 Super Duty, 2007 Ford F450 Super Duty, and 2007 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 FRONT SUSPENSION - FOUR WHEEL DRIVE (4WD) article.
    2. Fig 1: Driveshaft Flange Bolt
    GF0006629Courtesy of FORD MOTOR CO.
    NOTE: Index-mark the driveshaft to the pinion flange to maintain correct driveline balance.
  2. Remove and discard the 4 driveshaft flange bolts. Position the driveshaft aside.
  3. Remove the cotter pin, retainer cap and the RH outer tie-rod end nut.
    • Discard the cotter pin.
    4. Fig 2: Disconnecting Tie-Rod End Using Special Tool
    G03904173Courtesy of FORD MOTOR CO.
  4. Using the special tool, disconnect the RH tie-rod and the drag link. Position the drag link aside.
  5. Remove the 10 bolts and the differential housing cover. Drain the lubricant.
    • Clean the gasket material from the differential housing and the differential housing cover.
    6. Fig 3: Bearing Cap & Differential Housing Marks
    GF0006660Courtesy of FORD MOTOR CO.
    NOTE: Prior to removal, note the stamped mating letters positioning on the bearing caps and the differential housing for correct reassembly.
  6. Remove the 4 bearing cap bolts and the 2 bearing caps.
    7. Fig 4: Spreading Differential Housing
    GF0006654Courtesy of FORD MOTOR CO.
    CAUTION: Do not spread the differential housing more than specified or damage to the housing may occur.
    NOTE: Install the C-clamp at the 12 and 6 o'clock positions to allow the horizontal spread of the housing. Use a safety strap to restrain the C-clamp from rotation.
    NOTE: Use a C-clamp with a minimum 15-inch opening and a 16,250 lb load limit.
    NOTE: Lubricate the threads of the forcing screw.
  7. Using a C-clamp and the dial indicator, spread the differential housing 0.38 mm (0.015 in).
    • Remove the dial indicator after spreading the differential housing.
  8. Using a pry bar, remove the differential with the bearing cups.
    • Remove the C-clamp after removing the differential.
    9. Fig 5: Checking Pinion Bearing Torque Preload
    GF0006619Courtesy of FORD MOTOR CO.
  9. Measure the pinion bearing torque preload. Record the reading.
    • Rotate the pinion with a N.m (lb-in) torque wrench. Record the torque necessary to maintain rotation of the pinion through several revolutions.
    10. Fig 6: Holding Pinion Flange With Special Tool
    G03919131Courtesy of FORD MOTOR CO.
  10. Using the special tool to prevent the flange from turning, remove and discard the pinion nut and washer.
    11. Fig 7: Marking Flange And Pinion Shaft
    GF0006620Courtesy of FORD MOTOR CO.
  11. Using the special tool, remove the flange.
    12. Fig 8: Tapping Pinion
    GF0006657Courtesy of FORD MOTOR CO.
    CAUTION: Do not damage the pinion, the bearings or the cup.
  12. Remove the pinion.
    • Using a soft-faced hammer, tap the pinion through the outer bearing. Remove the pinion through the rear of the differential housing.
    13. Fig 9: Removing Pinion Seal Using Special Tools
    G03883494Courtesy of FORD MOTOR CO.
  13. Using the special tools, remove and discard the pinion seal.
    14. Fig 10: Differential Pinion Bearing
    GF0006643Courtesy of FORD MOTOR CO.
  14. Remove the oil slinger and the differential pinion bearing.
  15. Using a suitable tool, remove the outer pinion bearing cup, the inner pinion bearing cup and the oil baffle.
    • Use 205-D055 and 205-D051 to remove the inner pinion bearing cup.
    • Use 205-D055 and 205-D054 to remove the outer pinion bearing cup.
    16. Fig 11: Inner Axle Shaft Oil Seals
    GF0006666Courtesy of FORD MOTOR CO.
  16. Using a suitable tool, drive the inner axle shaft oil seals out of the differential housing from the axle tubes. Discard the seals.
    17. Fig 12: Collapsible Spacer
    GF0006651Courtesy of FORD MOTOR CO.
  17. Remove and discard the collapsible spacer.
    18. Fig 13: Removing Differential Pinion Bearing
    GF0006658Courtesy of FORD MOTOR CO.
  18. Using the special tool, remove the differential pinion bearing.
    19. NOTE: Discard the drive pinion position shim if bent or nicked. Measure and record the shim thickness if discarding the shim.
  19. Remove the drive pinion position shim.
    20. NOTE: Always use new solvent when cleaning the bearings.
    NOTE: Do not spin dry the bearings with compressed air.
    NOTE: Oil the bearings immediately, to prevent rusting.
  20. Carry out the following inspection.
    • 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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