Disassembly And Assembly: Axle: Disassembly

WARNING: This page is about a different car, the 2003 Ford Pickup, 2003 Ford F550 Super Duty, 2003 Ford F450 Super Duty, 2003 Ford Excursion, and 2003 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Remove the front wheel hubs and the front axle shaft assemblies. Refer to FRONT - 4WD LEAF SPRING - EXCURSION, F250-F550 SUPER DUTY PICKUPS .
Remove the front axle assembly. Refer to Axle Assembly .
- Place the axle assembly in a suitable repair stand.
Remove the differential housing cover and drain the lubricant.
- Position the differential housing to allow the lubricant to drain completely.
- Clean the gasket material from the differential housing and the differential housing cover.
  
  Fig 1: Cleaning Gasket Material From Differential Housing And Differential Housing Cover
  Courtesy of FORD MOTOR CO.

NOTE: An inspection can find the cause of the concern and determine the resolution.

Carry out the following inspection.
- Remove all the lubricant from the internal parts and visually inspect the parts for wear and damage.
- Rotate the gears to check for roughness, indicating damage to the bearings/gears.
- Check the teeth of the ring gear and pinion for signs of scoring, wear, nicks and chips.
  
  Fig 2: Checking Teeth Of Ring Gear And Pinion For Signs Of Scoring
  Courtesy of FORD MOTOR CO.

CAUTION: The differential ring gear and pinion must be clean and dry to obtain an accurate reading.

Using the special tools, measure the ring gear and pinion backlash at three equally spaced points. Record the reading.
- The backlash tolerance must be within the specification and cannot very more than 0.05 mm (0.002 in) between points checked. A backlash variation or more than 0.05 mm (0.002 in) indicates gear/case runout.
  - Make corrections for high or low backlash during assembly by changing the differential bearing selective shim thickness.
    
    Fig 3: Measuring Ring Gear And Pinion Backlash At Three Equally Spaced Points
    Courtesy of FORD MOTOR CO.

CAUTION: Prior to removal, note the stamped mating letters positioning on the bearing caps and the differential housing for correct reassembly.

Fig 4: Removing Bearing Caps

Courtesy of FORD MOTOR CO.

Remove the bearing caps.

CAUTION: Do not spread the differential housing more than specified.

Using the special tools, spread the differential housing.
- Remove special tool 100-D002 after spreading the differential housing.
  
  Fig 5: Removing Differential Housing
  Courtesy of FORD MOTOR CO.

CAUTION: Do not damage the ring gear and pinion.

Using two pry bars, remove the differential (4026) with the bearing cups.
- Remove special tool 205-001 after removing the differential.
- For differential disassembly, refer to Differential Case .
  
  Fig 6: Removing Differential With Bearing Cups
  Courtesy of FORD MOTOR CO.
Measure the pinion bearing torque preload. Record the reading.
- Rotate the pinion with a Nm (inch-pound) torque wrench. Record the torque necessary to maintain rotation of the pinion through several revolutions.
  
  Fig 7: Measuring Pinion Bearing Torque Preload
  Courtesy of FORD MOTOR CO.
Remove and discard the nut and washer.
- Use the special tool to prevent the flange from turning while removing the nut.
  
  Fig 8: Removing And Discard Nut And Washer
  Courtesy of FORD MOTOR CO.

NOTE: Index-mark the flange and the pinion shaft.

Fig 9: Removing Flange

Courtesy of FORD MOTOR CO.

Using the special tool, remove the flange.

CAUTION: Do not damage the pinion, the bearings, or the cup.

Remove the pinion.
- Using a soft face hammer, tap the pinion through the outer bearing. Remove the pinion through the rear of the differential housing.
  
  Fig 10: Removing Pinion
  Courtesy of FORD MOTOR CO.
Using the special tools, remove the pinion seal. Discard the seal.

Fig 11: Removing Pinion Seal
Courtesy of FORD MOTOR CO.
Remove the oil slinger and the differential pinion bearing.
- On model 50 axles, remove the collapsible spacer after removing the slinger and the bearing.
  
  Fig 12: Removing Oil Slinger And Differential Pinion Bearing
  Courtesy of FORD MOTOR CO.
Using the special tools, remove the outer pinion bearing cup, the inner pinion bearing cup, and the oil baffle.
- For model 50 axles, use special tool 205-D055 and 205-D054 to remove the inner and the outer pinion bearing cups.
- For model 60 axles, use special tool 205-D055 and 205-D051 to remove the inner pinion bearing cup.
- For model 60 axles, use special tool 205-D055 and 205-D054 to remove the outer pinion bearing cup.
  
  Fig 13: Removing Outer Pinion Bearing Cup
  Courtesy of FORD MOTOR CO.
Drive the inner axle shaft oil seals out of the differential housing through the axle tubes. Discard the seals.

Fig 14: Identifying Inner Axle Shaft Oil Seals Out Of Differential Housing Through Axle Tubes
Courtesy of FORD MOTOR CO.
On model 60 axles, remove the discard the collapsible spacer.

Fig 15: Removing Discard Collapsible Spacer
Courtesy of FORD MOTOR CO.
Using the special tool, remove the differential pinion bearing (4630).

Fig 16: Removing Differential Pinion Bearing
Courtesy of FORD MOTOR CO.

NOTE: Discard the drive pinion position shim if bent or nicked. Measure and record the shim thickness if discarding the shim.

Remove the drive pinion position shim.
Carry out the following inspection.
- Thoroughly clean all parts, including the differential housing and inside of the differential case.
- Inspect all parts for damage.
  - Discard the complete differential if excessive wear is visible on all parts.
  - Discard both differential pinion gears and both differential side gears if any one of these gears are worn/damaged.
  - Inspect the flange lugs for damage. The end of the flange that contacts the bearing cone as well as the nut counterbore and the seal contact area must be smooth and free of nicks.
  - Verify that the differential and pinion bearing bores are smooth. Remove any nicks/burrs from the mounting surfaces of the differential housing.