Differential Case: Removal

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

Raise and support the vehicle.
Remove the differential housing cover.
1. Remove the 12 differential housing cover bolts and drain the lubricant from the rear axle housing.
2. Remove the differential housing cover.
  
  Fig 1: Draining Lubricant From Rear Axle Housing
  Courtesy of FORD MOTOR CO.
Remove the axle shafts. Refer to Axle Assembly .
Wipe the lubricant from the internal working parts, and visually inspect the parts for wear or damage.
Rotate the differential case to see if there is any roughness which would indicate damaged bearings or gears.

Fig 2: Rotating Differential Case
Courtesy of FORD MOTOR CO.

NOTE: There is a space between the anti-lock speed sensor ring and the ring gear for measuring ring gear backface runout.

Fig 3: Inspecting Ring Gear Backlash And Ring Gear Backface Runout

Courtesy of FORD MOTOR CO.

Positioning the special tool, inspect ring gear backlash and ring gear backface runout.

CAUTION: Mark the position of the bearing caps, as arrows may not be visible. The bearing caps must be installed in their identical locations and positions.

Loosen the differential case.
1. Remove the bearing cap bolts.
2. Remove the bearing caps.
  
  Fig 4: Removing Bearing Cap Bolts
  Courtesy of FORD MOTOR CO.
To simplify the installation, fabricate two differential case retaining straps from metal stock as shown.

Fig 5: Fabricating Differential Case Retaining Straps From Metal Stock
Courtesy of FORD MOTOR CO.

WARNING: Be careful not to allow the differential case to fall.

CAUTION: Place a wood block between the pry bar and the rear axle housing to protect the machined surface from damage.

Fig 6: Removing Differential Case From Rear Axle Housing

Courtesy of FORD MOTOR CO.

Use the pry bar and the wood block to remove the differential case from the rear axle housing.
Remove the ring gear bolts.

Fig 7: Removing Ring Gear Bolts
Courtesy of FORD MOTOR CO.

CAUTION: Care should be taken not to damage the ring bolt hole threads.

NOTE: The anti-lock speed sensor ring cannot be reused once removed.

Fig 8: Inserting Punch In Bolt Holes

Courtesy of FORD MOTOR CO.

Insert a punch in the bolt holes. Drive off the ring gear and, if necessary, the anti-lock speed sensor ring.
Install the differential case without the ring gear.
1. Position the differential case assembly, including bearing clips and shims, in the housing.
2. Install the differential bearing caps.
3. Install the differential bearing cap bolts.
  
  Fig 9: Installing Differential Bearing Cap Bolts
  Courtesy of FORD MOTOR CO.

NOTE: Rotate the differential case to make sure the differential bearings are properly seated.

NOTE: If runout is within specification, install a new ring gear and pinion. If runout exceeds specification, the ring gear is true and the concern is due to either a damaged differential case or differential bearings. Inspect the differential bearings. If the differential bearings are not damaged, replace both the differential case and the differential bearings.

Measure the differential case runout by rotating the differential case.
Remove the differential case from the rear axle housing, and prepare to remove the differential bearings.
1. Position the Step Plate.
2. Position the Carrier Bearing Remover (Forcing Screw) and the Remover and Replacer Tube.
3. Position the Side Carrier Bearing Collets.
  
  Fig 10: Measuring differential case runout by rotating differential case
  Courtesy of FORD MOTOR CO.
Fig 11: Positioning Side Carrier Bearing Collets
Courtesy of FORD MOTOR CO.
Position the special tool.

Fig 12: Positioning Special Tool
Courtesy of FORD MOTOR CO.
Using two wrenches, remove the differential bearing.
- Repeat the procedure for the other differential bearing.
Fig 13: Removing Differential Bearing
Courtesy of FORD MOTOR CO.
Using the special tool, install the new differential bearings on the differential case.

Fig 14: Installing Differential Bearings On Differential
Courtesy of FORD MOTOR CO.
Measure the differential case runout without the ring gear.
- Check the case runout again with the new differential bearings. If the runout is now within the specification shown, use the new differential bearings for assembly. If the runout is still excessive, the differential case is damaged and must be replaced.
  
  Fig 15: Measuring Differential Case Runout Without Ring Gear
  Courtesy of FORD MOTOR CO.