Axle Assembly: Disassembly

WARNING: This page is about a different car, the 2004 Ford Pickup and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Raise the vehicle on a hoist or raise the rear end of the vehicle with a jack. Install safety stands under the frame rails and lower the jack or hoist enough to allow the rear axle to drop into the rebound position for working clearance. Refer to JACKING & LIFTING .
Remove the differential housing cover and drain the lubricant from the rear axle.
- Clean the gasket material from the differential housing cover and the differential housing.

NOTE: An inspection can find the cause of the concern and determine the resolution.

Carry out the following before disassembly.
- Remove all the lubricant from the internal parts of the conventional differential assembly or Trac-Lok® differential assembly. Visually inspect the parts for wear and damage.
- Rotate the differential assembly to check for any roughness, indicating damaged bearings or gears.
- Remove all the lubricant and check the differential ring gear and pinion teeth for signs of scoring, abnormal wear, nicks and chips.
- Use a magnet to search for heavy metal particles indicating component damage.
  
  Fig 1: Checking Differential Ring Gear And Pinion Teeth
  Courtesy of FORD MOTOR CO.

CAUTION: The differential ring gear and pinion must be clean and dry to obtain an accurate reading.

NOTE: Measure the differential ring gear and pinion backlash at three equally spaced points.

Using the special tools, measure the differential ring gear and pinion backlash.
- The backlash tolerance is 0.13-0.20 mm (0.005-0.008 in) and cannot vary more than 0.05 mm (0.002 in) between points checked. A backlash variation of more than 0.05 mm (0.002 in) indicates gear/case runout.
- Move the differential ring gear toward the pinion to correct high backlash.
- Move the differential ring gear away from the pinion to correct low backlash.
  
  Fig 2: Measuring Differential Ring Gear And Pinion Backlash
  Courtesy of FORD MOTOR CO.
Remove the axle shafts. Refer to REAR DRIVE AXLE/DIFFERENTIAL - DANA S135 .
Index-mark the driveshaft components to maintain driveline balance during assembly.

Fig 3: Identifying Index-Mark
Courtesy of FORD MOTOR CO.
Disconnect the driveshaft from the axle flange.
1. Remove and discard the bolts.
2. Remove and discard the U-joint retainers.
  - Using mechanic's wire, support the driveshafts.
    
    Fig 4: Removing U-Joint Retainers Bolts
    Courtesy of FORD MOTOR CO.

CAUTION: Note the positions of the mating letters stamped vertically and horizontally on the bearing caps and the differential housing before removing the bearing caps. Matching the letters is important at the time of assembly.

Fig 5: Identifying Mating Letters

Courtesy of FORD MOTOR CO.

To ease removal of the differential assembly, loosen the bolts, then pry the differential case, bearing cups and outboard spacers outward until they are loose in the differential housing.
Remove the bolts and the bearing caps.

CAUTION: Do not spread the differential housing more than specified.

Fig 6: Spreading Differential Housing Using Special Tools

Courtesy of FORD MOTOR CO.

Using the special tools, spread the differential housing to the specification, then remove the Dial Indicator Gauge with Holding Fixture.

CAUTION: It will be necessary to use large pry bars to remove the differential assembly from the differential housing. Do not damage the differential ring rear when carrying out this step.

CAUTION: Mark or tag the differential bearing cups, indicating from which side they were removed.

Remove the differential assembly with the bearing cups.
- Inspect the differential bearing cups for deep scores, galling and spelling. Discard them if necessary.
  
  Fig 7: Removing Differential Assembly With Bearing Cups
  Courtesy of FORD MOTOR CO.

CAUTION: Mark or tag the outboard spacer(s) indicating from which side they were removed.

Remove the outboard spacer(s).
- Inspect the spacer(s) for nicks, bending and grooved conditions. Discard them if necessary.
  
  Fig 8: Removing Outboard Spacers
  Courtesy of FORD MOTOR CO.
Remove the ring dear bolts.

Fig 9: Removing Ring Gear Bolts
Courtesy of FORD MOTOR CO.

CAUTION: Care should be taken not to damage the ring bolt hole threads.

NOTE: The anti-lock speed sensor ring cannot be reused once removed.

Fig 10: Removing Anti-Lock Speed Sensor Ring

Courtesy of FORD MOTOR CO.

Insert a punch in the bolt holes. Drive the ring gear and, if necessary, the anti-lock speed sensor ring.
Install the differential case without the ring gear.
1. Position the differential case assembly, including bearing clips and shims, in the housing.
2. Install the differential bearing caps.
3. Install the differential bearing cap bolts.
  - Loosen the special tool.
    
    Fig 11: Installing Differential Case Without Ring Gear
    Courtesy of FORD MOTOR CO.

NOTE: If runout is within specification, install a new ring gear and pinion. If runout exceeds specification, the ring gear is true and the concern is due to either a damaged differential case or differential bearings. Inspect the differential bearings. If the differential bearings are not damaged, install a new differential case and differential bearings.

NOTE: Rotate the differential case to make sure the differential bearings are correctly seated.

Fig 12: Measuring Differential Case Runout

Courtesy of FORD MOTOR CO.

Measure the differential case runout by rotating the differential case.
Remove the differential case from the rear axle housing.

CAUTION: Index-mark the pinion flange (4851) to the pinion shaft prior to removal.

Fig 13: Removing Lock Nut And Washer Using Special Tool

Courtesy of FORD MOTOR CO.

Use a suitable tool to prevent the flange from turning, and remove the lock nut and washer.
Using the special tool, remove the pinion flange.

Fig 14: Removing Pinion Flange Using Special Tool
Courtesy of FORD MOTOR CO.

NOTE: There are drive pinion bearing preload shims on the spline-end of the pinion. These shims can stick to the pinion, the pinion bearing or they can fall out of the differential housing. Collect and keep the shims for reassembly.

Fig 15: Removing Pinion Out Of Pinion Bearing Cup Using Special Tool

Courtesy of FORD MOTOR CO.

Using a soft faced hammer and the special tool, tap the pinion out of the pinion bearing cup and remove it through the rear of the differential housing.
Using the special tools, remove and discard the pinion seal.

Fig 16: Removing Pinion Seal Using Special Tools
Courtesy of FORD MOTOR CO.
Remove the oil slinger and the pinion bearing.

CAUTION: Do not nick the differential housing bore.

Fig 17: Removing Outer Pinion Bearing Cup Using Special Tools

Courtesy of FORD MOTOR CO.

Using the special tools, remove the outer pinion bearing cup.
Using the special tools, remove the inner pinion bearing cup.

Fig 18: Removing Inner Pinion Bearing Cup Using Special Tools
Courtesy of FORD MOTOR CO.
The oil slinger, if so equipped, is part of the total drive pinion position shim height required to correctly set pinion depth. Keep the oil slinger intact for assembly.

Fig 19: Identifying Oil Slinger
Courtesy of FORD MOTOR CO.
Using the special tools, remove the inner pinion bearing.

Fig 20: Removing Inner Pinion Bearing Using Special Tools
Courtesy of FORD MOTOR CO.

NOTE: Discard the drive pinion position shim if bent or nicked. If discarding the shim, measure and record the shim thickness.

Remove the oil slinger, if so equipped, and the drive pinion position shim.
Carry out the following after disassembling the axle:
- Thoroughly clean all parts.
- Inspect all parts for damage and wear.
- Clean the inside of the differential case before assembly. For Truetrac® differentials, submerge the entire differential assembly in a suitable solvent to wash away contaminates from within the housing.
- Thoroughly clean the differential housing if gears have scores/chips in them.