Differential Carrier: Removal

WARNING: This page is about a different car, the 2011 Ford Pickup and 2011 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 10 differential housing cover bolts and the differential housing cover.
- Drain the lubricant from the rear axle.
Clean the gasket material from the differential housing cover and the differential housing.
Remove the axle shafts. For additional information, refer to WHEEL HUBS AND BEARINGS - FULL FLOATING AXLE - DANA .
Remove the 4 bolts and the 2 bearing caps.
NOTE: Note the positions of the mating letters stamped vertically and horizontally on the bearing caps and the differential housing before removing the bearing caps.

Fig 1: Locating Differential Bearing Caps
Courtesy of FORD MOTOR CO.
Using the Dial Indicator Gauge with Holding Fixture and Differential Carrier Spreader, spread the differential housing.
NOTE: Do not spread the differential housing more than specified or damage to the housing may occur.

Fig 2: Spreading Differential Housing Using Differential Carrier Spreader
Courtesy of FORD MOTOR CO.
Remove the differential assembly with the bearing cups.
NOTE: It will be necessary to use large pry bars to remove the differential carrier from the differential housing. Do not damage the differential ring rear when carrying out this step.

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

Fig 3: Removing Differential Assembly With Bearing Cups
Courtesy of FORD MOTOR CO.
Remove the outboard spacers.
NOTE: Mark or tag the outboard spacers indicating from which side they were removed.
- Inspect the spacers for nicks, bending and grooved conditions. Discard them if necessary.
Fig 4: Locating Spacers
Courtesy of FORD MOTOR CO.