Differential Case and Ring Gear: Disassembly

All differentials 

NOTE: Differential bearing shims are available in thicknesses of 0.762, 0.787, 0.813, 0.838, 0.864, 0.889 and 0.914 mm (0.030, 0.031, 0.032, 0.033, 0.034, 0.035 and 0.036 in).
NOTE: If damaged, install new differential bearing shims.
NOTE: Install new differential bearings if removing them from the differential case.
1. Using the special tool, remove the differential bearings.
   • Wire the differential bearing shims, differential bearing cup, differential bearing, and selective outboard spacer(s) together. Note from which side they were removed (differential ring gear side or the opposite side).
     Fig 1: Removing Differential Bearings Using Special Tool

     Courtesy of FORD MOTOR CO.
NOTE: Use a vise with brass jaws or wood blocks.
2. Place the differential case in a vise.
CAUTION: Do not damage the anti-lock speed sensor ring when removing the differential ring gear. If removing the anti-lock speed sensor ring, discard it and install a new one.
NOTE: Always install new bolts upon assembly. Use Grade 9 bolts for all Dana rear axles.
Fig 2: Removing Bolts
Courtesy of FORD MOTOR CO.
3. Remove the bolts. Leave four bolts loosely assembled, 90 degrees apart.
4. Tap each bolt head alternately with a rawhide or plastic hammer to loosen the differential ring gear. Remove the bolts and the differential ring gear.
   Fig 3: Taping Each Bolt Head Alternately With Rawhide Or Plastic Hammer

   Courtesy of FORD MOTOR CO.
5. If necessary, remove the anti-lock speed sensor ring with a soft-faced hammer. Discard the anti-lock speed sensor ring.
   Fig 4: Removing Anti-Lock Speed Sensor Ring With Soft-Faced Hammer

   Courtesy of FORD MOTOR CO.
6. The Truetrac® and Trac-Lok® differential assemblies are non-repairable. Discard the entire assembly if it is worn/damaged. For conventional differential assemblies, proceed as follows.
   Fig 5: Identifying Truetrac® Differential Assemblies

   Courtesy of FORD MOTOR CO.
   Fig 6: Identifying Trac-Lok® Differential Assemblies

   Courtesy of FORD MOTOR CO.

   Conventional differential 

NOTE: Use a vise with brass jaws or wood blocks.
7. Place the differential case in a vise.
8. Using a small drift, drive out the differential pinion shaft lock pin.
   Fig 7: Driving Out Differential Pinion Shaft Lock Pin Using Small Drift

   Courtesy of FORD MOTOR CO.
9. Using a drift, remove the differential pinion shaft.
   Fig 8: Removing Differential Pinion Shaft Using Drift

   Courtesy of FORD MOTOR CO.
10. To remove the differential side gears and the differential pinion gears, rotate the differential side gears. The differential pinion gears will turn to the opening in the differential case.
    Fig 9: Removing Differential Side Gears

    Courtesy of FORD MOTOR CO.
11. Remove the differential pinion gears and the differential pinion thrust washers behind the differential pinion gears.
12. Lift out the differential side gears and the differential side gear thrust washers.