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Home >> Ford >> 2002 >> Taurus SES, 3.0 2, AX4S >> Repair and Diagnosis >> External Pages >> Different car >> Section 398 (Rear Drive Axle/Differential - DANA S135 -- F450-F550 Super Duty) >> In-Vehicle Repair >> Differential Carrier >> Removal

Differential Carrier: Removal

WARNING: This page is about a different car, the 2003 Ford F550 Super Duty and 2003 Ford F450 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: Do not use heat when disassembling a drive axle. To do so will destroy heat treat properties and weaken or distort axle components. Failure to follow these instructions may result in personal injury.
    CAUTION: Steam clean the axle prior to removal from the vehicle. Dirt is abrasive and will cause premature wear of otherwise usable parts.
  1. Steam clean the axle assembly.
  2. Set the parking brake.
    Fig 1: Setting Parking Brake
    G01551047Courtesy of FORD MOTOR CO.
  3. Chock the wheels.
    Fig 2: Chocking Wheels
    G01551048Courtesy of FORD MOTOR CO.
  4. Drain the axle lubricant into a suitable container.
    1. Remove the drain plug.
    2. Clean and install the drain plug when the lubricant has drained.
      Fig 3: Removing Drain Plug
      G01551049Courtesy of FORD MOTOR CO.
  5. Disconnect the rear anti-lock brake sensor electrical connector.
    Fig 4: Disconnecting Rear Anti-Lock Brake Sensor Electrical Connector
    G01551050Courtesy of FORD MOTOR CO.
  6. Index-mark and disconnect the driveshaft, and position it aside. Refer to DRIVESHAFT .
    Fig 5: Index-Marking And Disconnecting Driveshaft
    G01551051Courtesy of FORD MOTOR CO.
  7. Loosen the pinion hex nut if drive pinion disassembly is necessary.
    Fig 6: Loosening Pinion Hex Nut
    G01551052Courtesy of FORD MOTOR CO.
    8. WARNING: Do not strike the axle shaft flange directly with a steel hammer or sledge. This will crack and splinter the flange. Failure to follow these instructions may result in personal injury.
    CAUTION: Do not pry or chisel the axle shaft flange away from the hub. This will damage the sealing surface.
    NOTE: Mark the left or right axle shaft flange for proper orientation during installation.
    Fig 7: Removing Bolts
    G01551053Courtesy of FORD MOTOR CO.
  8. Remove the axle shafts. Refer to WHEEL HUBS & BEARINGS-FULL FLOATING AXLE-DANA .
  9. Remove all but the two top carrier-to-axle housing retaining bolts, noting the length and position of each bolt.
    Fig 8: Removing Carrier-To-Axle Housing Retaining Bolts
    G01551054Courtesy of FORD MOTOR CO.
    10. WARNING: Secure the carrier to the jack to prevent it from falling when removing it from the axle housing. Failure to follow these instructions may result in personal injury.
  10. Remove the carrier from the axle housing.
    1. Position a suitable jack under the carrier.
    2. Remove the remaining retaining bolts.
    3. Use the slots to separate the carrier approximately 25.4-50.8 mm (1-2 inches) from the axle housing.
    4. Secure the carrier to a suitable jack, and remove the carrier from the axle housing.
      Fig 9: Removing Carrier From Axle Housing
      G01551055Courtesy of FORD MOTOR CO.
    11. CAUTION: Alkaline cleaning solutions will damage machine surfaces. Use only emulsion cleaners or petroleum based cleaning solvent.
    CAUTION: Use only soft, clean, lintless towels to dry the components.
    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.
  11. Clean and dry the components as necessary.
    12. NOTE: The gear set shown removed for clarity.
    Fig 10: Inspecting Gear Set
    G01551056Courtesy of FORD MOTOR CO.
  12. Inspect the gear set for pitting, scoring, wear and damage.
  13. Inspect the splines for wear, cracking and distortion from twisting.
    Fig 11: Inspecting Splines For Wear
    G01551057Courtesy of FORD MOTOR CO.
  14. Inspect the axle flange O-ring.
    Fig 12: Inspecting Axle Flange O-Ring
    G01551058Courtesy of FORD MOTOR CO.
  15. 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.
    Fig 13: Inspecting Housing For Stripped And Damaged Threads
    G01551059Courtesy of FORD MOTOR CO.
  16. If carrier disassembly is necessary, refer to Differential Case and Ring Gear .
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