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Home >> Ford >> 2002 >> Excursion 6.8 S, RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 316 (Rear Drive Axle/Differential - DANA S135 -- F450-F550 Super Duty) >> Disassembly And Assembly >> Differential Case and Ring Gear >> Disassembly

Differential Case and Ring Gear: Disassembly

WARNING: This page is about a different car, the 2002 Ford F550 Super Duty and 2002 Ford F450 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.
  1. Mount the carrier housing (4141) in a suitable repair stand.
    Fig 1: Mounting Carrier Housing (4141) In A Suitable Repair Stand
    G02172937Courtesy of FORD MOTOR CO.
    2. CAUTION: If reusing the differential ring gear and pinion (4209) measure and record the backlash before disassembly. Re-assembling the differential ring gear and pinion to the recorded backlash will match the established wear patterns. Hand rolled patterns will cover less area than the established patterns.
    Fig 2: Measuring And Record Differential Ring Gear And Pinion Backlash
    G02172938Courtesy of FORD MOTOR CO.
  2. Measure and record the differential ring gear and pinion backlash.
    • Check the backlash in four equally spaced positions around the differential ring gear.
    • The acceptable backlash tolerance is +/- 0.0508 mm (0.002 inch) from the backlash etched in the differential ring gear.
    • The tooth contact pattern can move only by adjusting backlash. The tooth contact pattern can move only in the direction of heel-to-toe, and toe-to-heel. Depth of the tooth contact pattern is not adjustable. Contact Spicer Service at 1-800-666-8688 for assistance if you are unable to establish an acceptable tooth contact pattern within the limits of backlash.
  3. Remove the rear anti-lock brake sensor.
    Fig 3: Removing Rear Anti-Lock Brake Sensor
    G02172939Courtesy of FORD MOTOR CO.
  4. Remove the adjusting ring locks (4143).
    Fig 4: Removing Adjusting Ring Locks (4143)
    G02172940Courtesy of FORD MOTOR CO.
  5. Loosen, but do not remove, the four bolts.
    Fig 5: Removing Four Bolts
    G02172941Courtesy of FORD MOTOR CO.
  6. Relieve the bearing preload.
    • Loosen each differential bearing adjusting ring (4067).
    Fig 6: Relieving Bearing Preload
    G02172942Courtesy of FORD MOTOR CO.
    7. NOTE: The differential bearing caps are match marked at the factory.
    Fig 7: Removing Bearing Caps Bolts
    G02172943Courtesy of FORD MOTOR CO.
  7. Remove the bolts, bearing caps and adjusting rings.
    8. CAUTION: Do not damage the differential ring gear and pinion.
    Fig 8: Removing Differential Subassembly Out Of Carrier
    G02172944Courtesy of FORD MOTOR CO.
  8. Using the special tool, carefully lift the differential subassembly out of the carrier.
  9. Using the special tool, and a suitable puller, remove the differential side bearings (4221) if worn/damaged.
    Fig 9: Removing Differential Side Bearings
    G02172945Courtesy of FORD MOTOR CO.
  10. The Truetrac® differential assembly is non-repairable. Discard the entire assembly if it is worn/damaged.
    Fig 10: Locating Bolts
    G02172946Courtesy of FORD MOTOR CO.
  11. On the conventional differential assembly (4026) separate the differential case halves (4204).
    1. Match mark the case halves.
    2. Remove the bolts.
    3. Separate the case halves.
    Fig 11: Separating Case Halves
    G02172947Courtesy of FORD MOTOR CO.
  12. On the conventional differential assembly, remove the gear assembly.
    1. Remove the thrust washer (4228) and differential side gear (4237).
    2. Remove the differential cross shaft (4211) with the pinion mates and the thrust washers (4230).
    3. Remove the differential side gear and thrust washer.
    Fig 12: Removing Differential Side Gear And Thrust Washer
    G02172948Courtesy of FORD MOTOR CO.
    Fig 13: Identifying Correct Way Of Disassembly And Assembly Rivet
    G02172949Courtesy of FORD MOTOR CO.
    13. CAUTION: Do not use a chisel to remove the rivet heads. This will damage the differential case.
    CAUTION: Use a soft hammer to strike the punch.
  13. If discarding the pinion/differential ring gear, carefully center punch each differential ring gear rivet.
  14. Drill the rivet heads to the depth shown using the specified size drill bit.
    Fig 14: Drilling Rivet Heads
    G02172950Courtesy of FORD MOTOR CO.
  15. Separate the differential ring gear from the case.
      CAUTION: Use a soft hammer to strike the punch.
    1. Drive out the remaining rivet portions with a rounded type punch.
    2. Separate the differential ring gear from the case.
      3. CAUTION: Discard the anti-lock speed sensor ring (4B409) if separating it from the case half.
    3. If necessary, remove the anti-lock speed sensor ring and discard it.
    Fig 15: Removing Rivet
    G02172951Courtesy of FORD MOTOR CO.
    16. CAUTION: Alkaline cleaning solutions will damage machine surfaces. Use only emulsion cleaners or petroleum based cleaning solvent.
    CAUTION: Use soft, clean, lintless towels to dry the components.
    CAUTION: Never spin-dry bearings with compressed air. This will damage the mating surfaces due to a lack of lubrication.
    CAUTION: 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.
    NOTE: For Truetrac® differentials, submerge the entire differential assembly in a suitable solvent to wash away contaminants from within the housing.
  16. Clean and dry the components.
  17. Inspect the bearing surfaces for pitting, wear and overheating.
    Fig 16: Inspecting Bearing Surfaces
    G02172952Courtesy of FORD MOTOR CO.
  18. Inspect the following:
    • The differential case machine surfaces.
    • The differential ring gear mounting holes for deformities, such as egg shaping.
    • All surfaces for nicks and cracks.
    Fig 17: Inspecting Differential Ring Gear Mounting Holes
    G02172953Courtesy of FORD MOTOR CO.
  19. Inspect the thrust washers for scoring and cracking.
    Fig 18: Inspecting Thrust Washers For Scoring And Cracking
    G02172954Courtesy of FORD MOTOR CO.
    20. CAUTION: Discard all gears in sets if one or more sustains wear/damage.
    Fig 19: Inspecting Gears For Pitting
    G02172955Courtesy of FORD MOTOR CO.
  20. Inspect the gears for pitting, scoring, wear and damage.
  21. Inspect the shafts for nicks and scores.
    Fig 20: Inspecting Shafts For Nicks And Scores
    G02172956Courtesy of FORD MOTOR CO.
  22. Refer to DRIVE PINION  if disassembly is necessary.
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