Differential Case: 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.

Remove the differential carrier. For additional information, refer to Differential Carrier - Dana 60 .

Fig 1: Removing Differential Bearings Using Special Tool

Courtesy of FORD MOTOR CO.

Using the special tool, remove the differential bearings.

Fig 2: Differential Bearing Shim

Courtesy of FORD MOTOR CO.

Remove the differential bearing shims.

Fig 3: Tapping Ring Gear Bolts

Courtesy of FORD MOTOR CO.

CAUTION: Place shop towels under the ring gear to prevent ring gear damage.

NOTE: Discard the bolts after removing them from the differential case.

Remove the ring gear.
- Remove and discard 8 of the 12 ring gear bolts. Leave 4 loosely assembled bolts spaced equally apart from each other.
- Tap each of the 4 bolt heads alternately with a soft-faced hammer to loosen the ring gear. Remove the bolts and the ring gear. Discard the bolts.

Fig 4: Differential Pinion Shaft Lockpin

Courtesy of FORD MOTOR CO.

Using a hammer and a small drift, drive out the differential pinion shaft lockpin.

Fig 5: Differential Pinion Shaft

Courtesy of FORD MOTOR CO.

Using a suitable tool, remove the differential pinion shaft.

Fig 6: Differential Side Gear & Thrust Washer

Courtesy of FORD MOTOR CO.

Remove the differential pinion gears, pinion gear thrust washers, differential side gears and differential side gear thrust washers.

NOTE: If upon inspection, any component has score marks/chips, thoroughly clean the differential housing.

Carry out the following inspection.
- Thoroughly clean all parts.
- Inspect all parts for damage or discoloration from overheating.
  - 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.
- Verify that the differential bearing bores are smooth. Remove any nicks/burrs from the mounting surfaces of the differential housing.