Differential Carrier: Removal

All vehicles 

1. Set the parking brake.
2. Chock the wheels.
3. Remove the bottom 2 carrier bolts and drain the assembly.
   • Drain the axle lubricant into a suitable container.
   Fig 1: Locating Carrier Bolts

   Courtesy of FORD MOTOR CO.
4. Disconnect the rear wheel speed sensor electrical connector.
   Fig 2: Locating Rear Wheel Speed Sensor Electrical Connector

   Courtesy of FORD MOTOR CO.

   Vehicles with split pin yoke 

5. Index-mark the driveshaft and pinion flange for reassembly.
   Fig 3: Locating Index-Mark On Driveshaft And Pinion Flange

   Courtesy of FORD MOTOR CO.
6. Remove and discard the 4 driveshaft bolts and 2 U-joint straps.
   Fig 4: Locating Driveshaft Bolt And U-Joint Strap

   Courtesy of FORD MOTOR CO.

   Vehicles with circular flange 

7. Index-mark the driveshaft and pinion flange. Remove and discard the 4 bolts.

   All vehicles 

8. Position the driveshaft aside.
   NOTE: Do not allow the driveshaft to hang unsupported.
9. Loosen the pinion hex nut if drive pinion disassembly is necessary.
   Fig 5: Locating Pinion Hex Nut

   Courtesy of FORD MOTOR CO.
10. Remove the axle shafts. For additional information, refer to WHEEL HUBS AND BEARINGS - FULL FLOATING AXLE - DANA .
    NOTE: Do not strike the axle shaft flange directly with a steel hammer or sledge. This will crack and splinter the flange and damage the component.
    NOTE: Do not pry or chisel the axle shaft flange away from the hub. This will damage the sealing surface.
11. Remove all but the 2 top differential carrier housing bolts, noting the length and position of each bolt.
    • Discard the 10 differential carrier housing bolts.
    Fig 6: Locating Top Differential Carrier Housing Bolts

    Courtesy of FORD MOTOR CO.
12. Remove the carrier from the axle housing in the following sequence.
    WARNING: Secure the assembly to the jack. Avoid any obstructions while lowering and raising the jack. Contact with obstructions may cause the assembly to fall off the jack, which may result in serious personal injury.
    1. Position a suitable jack under the carrier.
    2. Remove and discard the 2 remaining top differential carrier housing bolts.
    3. Use the slots to separate the carrier approximately 25.4-50.8 mm (1-2 in) from the axle housing.
    4. Secure the carrier to a suitable jack and remove the carrier from the axle housing.
13. Clean and dry the components as necessary.
    NOTE: Alkaline cleaning solutions will damage machine surfaces. Use only emulsion cleaners or petroleum-based cleaning solvent.
    NOTE: Use only soft, clean, lintless towels to dry the components.
    NOTE: After drying, lightly coat the parts with rust inhibitor or clean lubricant to prevent damage from corrosion. Wrap all parts that are going to be in storage for a prolonged period in wax paper.
14. Inspect the gear set for pitting, scoring, wear or damage. Install new components as necessary.
    Fig 7: Locating Gear Set Wear

    Courtesy of FORD MOTOR CO.
15. Inspect the splines for wear, cracking or distortion from twisting.
    Fig 8: Locating Gear Splines Wear

    Courtesy of FORD MOTOR CO.
16. Inspect the axle flange O-ring.
    Fig 9: Locating Axle Flange O-Ring

    Courtesy of FORD MOTOR CO.
17. Clean the axle housing interior, the axle and carrier housing sealing surfaces and the carrier mounting bolt hole threads. Inspect the housing for stripped and damaged threads and bending fatigue. Repair or install new components as necessary.
    Fig 10: Locating Axle And Carrier Housing Sealing Surfaces

    Courtesy of FORD MOTOR CO.
18. If carrier disassembly is necessary, refer to DIFFERENTIAL CASE AND RING GEAR .