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Home >> Ford >> 2002 >> Taurus SES, 3.0 2, AX4S >> Repair and Diagnosis >> External Pages >> Different car >> Section 888 (Rear Drive Axle/Differential - DANA S110 -- 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 2004 Ford F550 Super Duty and 2004 Ford F450 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.
  1. Mount the carrier housing in a suitable repair stand.
    Fig 1: Mounting Carrier Housing In A Suitable Stand
    G02769048Courtesy of FORD MOTOR CO.
    2. CAUTION: If reusing the differential ring gear and pinion, measure and record the backlash before disassembly. 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.
  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 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.
      Fig 2: Checking Backlash In Four Equally Spaced Positions
      G02769049Courtesy of FORD MOTOR CO.
  3. Remove the rear anti-lock brake sensor.
    Fig 3: Removing Rear Anti-Lock Brake Sensor
    G02769050Courtesy of FORD MOTOR CO.
  4. Remove the adjusting ring cotter pins.
    Fig 4: Removing Adjusting Ring Cotter Pins
    G02769051Courtesy of FORD MOTOR CO.
  5. Loosen, but do not remove, the six bearing cap bolts.
    Fig 5: Removing Six Bearing Cap Bolts
    G02769052Courtesy of FORD MOTOR CO.
  6. Relieve the bearing preload.
    • Loosen each differential bearing adjusting ring.
      Fig 6: Loosening Each Differential Bearing Adjusting Ring
      G02769053Courtesy of FORD MOTOR CO.
  7. Remove the bolts, bearing caps and adjusting rings.
    Fig 7: Removing Bolts Bearing Caps And Rings
    G02769054Courtesy of FORD MOTOR CO.
  8. Carefully lift the differential subassembly out of the carrier.
  9. Inspect the bearing surfaces for pitting, wear and overheating.
    Fig 8: Inspecting Bearing Surfaces For Pitting Wear And Overheating
    G02769055Courtesy of FORD MOTOR CO.
  10. Using the special tools, remove the differential side bearings if worn or damaged.
    Fig 9: Removing Differential Side Bearings
    G02769056Courtesy of FORD MOTOR CO.
  11. Remove the twelve ring gear bolts.
    Fig 10: Removing Twelve Ring Gear Bolts
    G02769057Courtesy of FORD MOTOR CO.
  12. Place the differential assembly in a suitable press supported on the ring gear.
    Fig 11: Placing Differential Assembly
    G02769058Courtesy of FORD MOTOR CO.
    13. WARNING: The differential case will fall after separation. Support the case so it will not result in damage to the component or equipment. Failure to follow these instructions can result in personal injury.
    CAUTION: It should not require more than 3 tons of press load to separate the ring gear from the differential case.
    CAUTION: Do not bend the differential pinion cross shaft.
    Fig 12: Identifying Differential Pinion Cross Shaft
    G02769059Courtesy of FORD MOTOR CO.
  13. The press arbor will push on the differential pinion cross shaft to separate the ring gear half of the differential from the cross shaft half of the assembly.
    14. CAUTION: Discard the anti-lock speed sensor ring if separating it from the ring gear side case half.
    Fig 13: Discarding Anti-Lock Speed Sensor Ring
    G02769060Courtesy of FORD MOTOR CO.
  14. If necessary, remove the anti-lock speed sensor ring.
    15. CAUTION: Alkaline cleaning solutions will damage machine surfaces. Use only emulsion cleaners or petroleum-based cleaning solvents.
    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.
  15. Clean and dry the components.
  16. The Truetrac® differential assembly is non-repairable. Discard the entire assembly if it is worn or damaged.
    Fig 14: Cleaning And Dry Components
    G02769061Courtesy of FORD MOTOR CO.
  17. With a conventional differential, lift out the side gear.
    Fig 15: Lifting Out Side Gear
    G02769062Courtesy of FORD MOTOR CO.
  18. Remove the differential pinion cross shaft lock pin.
    Fig 16: Removing Differential Pinion Cross Shaft Lock Pin
    G02769063Courtesy of FORD MOTOR CO.
    19. CAUTION: Discard all gears in sets if one or more sustains wear or damage.
    Fig 17: Removing Pinion Cross Shaft
    G02769064Courtesy of FORD MOTOR CO.
  19. Remove the pinion cross shaft.
  20. Remove the inner side gear and thrust washer.
    Fig 18: Removing Inner Side Gear And Thrust Washer
    G02769065Courtesy of FORD MOTOR CO.
  21. Refer to DRIVE PINION  if disassembly is necessary.
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