Differential Case: 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.

CAUTION: Do not reuse the bearings after removing them from the differential case (4204).

Remove the differential bearings and the shims.
1. Place the differential (4026) into a vise with soft jaws.
2. Using the special tool, remove the differential bearing.
3. Remove the differential bearing shims (4067).
  - Wire the shims, the bearing cone, and the cup together. Identify from which side they were removed.
    - Repeat the procedure for the opposite side.
      
      Fig 1: Removing Differential Bearing
      Courtesy of FORD MOTOR CO.
      
      Fig 2: Removing Differential Bearing Shims
      Courtesy of FORD MOTOR CO.

CAUTION: Discard the bolts after removing them from the differential case.

CAUTION: Place shop towels under the ring gear to prevent ring gear damage.

Remove the ring gear.
1. Place the differential case into a vise with soft jaws.
2. Remove and discard all but four of the bolts. Leave four loosely assembled bolts spaced apart from each other.
3. Tap each bolt head alternately with a soft face hammer to loosen the ring gear. Remove the bolts and the ring gear. Discard the bolts.
  
  Fig 3: Removing Ring Gear
  Courtesy of FORD MOTOR CO.
Using a hammer and a small drift, drive out the differential pinion shaft lock pin (4241).

Fig 4: Identifying Differential Pinion Shaft Lock Pin
Courtesy of FORD MOTOR CO.
Remove the differential pinion shaft (4211).

Fig 5: Removing Differential Pinion Shaft (4211)
Courtesy of FORD MOTOR CO.
Remove the differential pinion gears (4215) and thrust washers, and the differential side gears (4236) and thrust washers.

Fig 6: Removing Differential Pinion Gears (4215)
Courtesy of FORD MOTOR CO.

CAUTION: Always use new solvent when cleaning the bearings.

CAUTION: Do not spin dry the bearings with compressed air.

CAUTION: Oil the bearings immediately, to prevent rusting.

CAUTION: If upon inspection, any component has score marks/chips, thoroughly clean the differential housing.

Carry out the following inspection.
- Thoroughly clean all parts.
- 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.
  - Verify that the differential bearing bores are smooth. Remove any nicks/burrs from the mounting surfaces of the differential housing.