Differential Ring And Pinion: Removal

WARNING: This page is about a different car, the 2008 Ford Pickup and 2008 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Remove the differential carrier assembly. For additional information, refer to Differential Carrier .
Using the Differential Carrier Bearing Step Plate, Differential Carrier Bearing Collets, Differential Carrier Bearing Retaining Ring, Bearing Tube Remover/Installer and Bearing Tube Remover Screw, remove the differential bearings.
- Place the left and right differential bearing shims with the respective outboard spacers.

Fig 1: Removing Differential Bearings Using Special Tools

Courtesy of FORD MOTOR CO.

NOTE: Use a vise with brass jaws or wood blocks.

Place the differential carrier in a vise.

NOTE: Whenever removing the differential ring gear bolts, always install new Grade 9 differential ring gear bolts.

Remove 8 of the differential ring gear bolts. Leave 4 differential ring gear bolts loosely assembled, 90 degrees apart.

Fig 2: Ring Gear Bolts (4 Remaining)

Courtesy of FORD MOTOR CO.

Tap each differential ring gear bolt head alternately with a rawhide or plastic hammer to loosen the differential ring gear. Remove the 4 differential ring gear bolts and the differential ring gear.
- Discard the differential ring gear bolts.

Fig 3: Tapping Ring Gear Bolts

Courtesy of FORD MOTOR CO.

If necessary, remove and discard the anti-lock speed sensor ring with a soft-faced hammer.

Fig 4: Anti-Lock Speed Sensor Ring

Courtesy of FORD MOTOR CO.

To maintain driveline balance, index-mark the driveshaft flange and the pinion flange.

Fig 5: Marking Driveshaft Flange & Pinion Flange

Courtesy of FORD MOTOR CO.

Remove the 4 bolts.

Fig 6: Driveshaft Flange Bolts

Courtesy of FORD MOTOR CO.

NOTE: The driveshaft flange fits tightly on the pinion flange. Using a suitable tool, pry only in the area shown to disconnect the driveshaft flange or damage to the driveshaft may occur.

NOTE: It may be necessary to tap the driveshaft flange with a plastic or rubber soft-faced hammer if a pry area is not on the driveshaft flange.

Using a suitable tool as shown, disconnect the driveshaft flange from the pinion flange and support the driveshaft using mechanic's wire.

Fig 7: Disconnecting Driveshaft Flange Yoke From Pinion Flange

Courtesy of FORD MOTOR CO.

Use the Drive Pinion Flange Holding Fixture to prevent the flange from turning while removing the lock nut and washer.

Fig 8: Holding Pinion Flange With Special Tool (205-126)

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Using the 2-Jaw Puller, remove the pinion flange.

Fig 9: Removing Pinion Flange Using Special Tool (205-D072)

Courtesy of FORD MOTOR CO.

NOTE: There are drive pinion bearing preload shims on the splined-end of the pinion shaft. These drive pinion bearing preload shims can stick to the pinion shaft, the pinion bearing or they can fall out of the axle housing. Collect and keep the drive pinion bearing preload shims for reassembly.

Using the Drive Pinion Thread Protector, drive the pinion from the outer pinion bearing and remove it through the rear of the axle housing.

Fig 10: Driving Pinion From Outer Pinion Bearing

Courtesy of FORD MOTOR CO.

Using the Slide Hammer and Bushing Remover, remove and discard the drive pinion seal.

Fig 11: Removing Pinion Seal Using Special Tools (100-001, 307-001)

Courtesy of FORD MOTOR CO.

Remove the drive pinion oil slinger, the outer drive pinion bearing and the pinion preload adjustment shims.

NOTE: Do not nick the axle housing bore or damage to the component may occur.

Using the Rear Wheel Hub Bearing Cup Remover and Handle, remove the outer pinion bearing cup.

Fig 12: Removing Outer Pinion Bearing Cup

Courtesy of FORD MOTOR CO.

Using the Drive Pinion Inner Bearing Remover and Handle, remove the inner pinion bearing cup.

Fig 13: Removing Inner Pinion Bearing Cup

Courtesy of FORD MOTOR CO.