Differential Case: Removal

WARNING: This page is about a different car, the 2010 Ford Pickup and 2010 Ford Cab & Chassis. 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 JACKING & LIFTING .
Remove the 12 differential housing cover bolts and drain the lubricant from the rear axle housing.

Fig 1: Locating Differential Housing Cover Bolts
Courtesy of FORD MOTOR CO.
Remove the differential housing cover.
Remove the axle shafts. For additional information, refer to WHEEL HUBS AND BEARINGS - FULL FLOATING AXLE - FORD .
Wipe the lubricant from the internal working parts and visually inspect the parts for wear or damage.
Rotate the differential case to see if there is any roughness which would indicate damaged bearings or gears.

Fig 2: Rotating Differential Case
Courtesy of FORD MOTOR CO.

NOTE: There is a space between the anti-lock speed sensor ring and the ring gear for measuring ring gear backface runout.

Fig 3: Inspecting Ring Gear Backlash And Ring Gear Backface Runout

Courtesy of FORD MOTOR CO.

Positioning the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, inspect ring gear backlash and ring gear backface runout.

NOTE: Mark the position of the bearing caps, as arrows may not be visible. The bearing caps must be installed in their identical locations and positions.

Loosen the differential case.
1. Remove the 4 bearing cap bolts.
2. Remove the 2 bearing caps.
  
  Fig 4: Identifying Bearing Cap And Bearing Cap Bolts
  Courtesy of FORD MOTOR CO.

NOTE: Place a wood block between the pry bar and the rear axle housing to protect the machined surface from damage.

Fig 5: Removing Differential Case From Rear Axle Housing

Courtesy of FORD MOTOR CO.

Use the pry bar and the wood block to remove the differential case from the rear axle housing.
Remove and discard the 12 ring gear bolts.

Fig 6: Locating Ring Gear Bolts
Courtesy of FORD MOTOR CO.

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

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

Fig 7: Driving Off Ring Gear

Courtesy of FORD MOTOR CO.

Insert a punch in the bolt holes. Drive off 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 2 differential bearing caps.
3. Install the 4 differential bearing cap bolts.
  - Tighten to 119 Nm (88 lb-ft).
    
    Fig 8: Identifying Differential Case Assembly With Differential Bearing Caps And Differential Bearing Cap Bolts
    Courtesy of FORD MOTOR CO.

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

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 damaged, install new differential bearings.

Fig 9: 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 and using the Differential Carrier Bearing Step Plate, Differential Carrier Bearing Retaining Ring, Differential Carrier Bearing Collets, Bearing Tube Remover and Bearing Tube Remover Screw, remove the differential bearings.

Fig 10: Removing Differential Bearings Using Special Tools
Courtesy of FORD MOTOR CO.
Using the Differential Carrier Bearing Installer, install new differential bearings on the differential case.

Fig 11: Installing Differential Bearings On Differential Case Using Special Tool
Courtesy of FORD MOTOR CO.
Measure the differential case runout without the ring gear.
- Check the case runout again with the new differential bearings. If the runout is now within the specification shown in illustration, use the new differential bearings for assembly. If the runout is still excessive, the differential case is damaged and a new differential case must be installed.
  
  Fig 12: Measuring Differential Case Runout
  Courtesy of FORD MOTOR CO.