Differential Ring And Pinion: Removal

WARNING: This page is about a different car, the 2010 Ford Pickup and 2010 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
  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.

Fig 2: Identifying Ring Gear

Courtesy of FORD MOTOR CO.

Remove and discard 8 of the differential ring gear bolts. Leave 4 differential ring gear bolts loosely assembled, 90 degrees apart.
Tap each differential ring gear bolt head alternately with a rawhide or plastic hammer to loosen the differential ring gear. Remove and discard the 4 differential ring gear bolts. Remove the differential ring gear.

Fig 3: Tapping Differential Ring Gear Bolt Head
Courtesy of FORD MOTOR CO.
If necessary, remove and discard the anti-lock speed sensor ring with a soft-faced hammer.

Fig 4: Removing Anti-Lock Speed Sensor Ring Using Soft-Faced Hammer
Courtesy of FORD MOTOR CO.
To maintain driveline balance, index-mark the driveshaft flange and the pinion flange.

Fig 5: Locating Index-Mark On Driveshaft Flange And Pinion Flange
Courtesy of FORD MOTOR CO.
Remove and discard the 4 driveshaft flange bolts.

Fig 6: Locating Driveshaft Flange Bolt
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 in illustration 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.

NOTE: Do not allow the driveshaft to hang unsupported.

Fig 7: Disconnecting Driveshaft Flange From Pinion Flange Using Suitable Tool

Courtesy of FORD MOTOR CO.

Using a suitable tool as shown in illustration, disconnect the driveshaft flange from the pinion flange and support the driveshaft using mechanic's wire.
Using the Drive Pinion Flange Holding Fixture to prevent the flange from turning, remove the pinion shaft locknut and washer.

Fig 8: Holding Pinion Flange Using Special Tool
Courtesy of FORD MOTOR CO.
Using the 2 Jaw Puller, remove the pinion flange.

Fig 9: Removing Pinion Flange Using Jaw Puller
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.

Fig 10: Removing Driving Pinion Through Rear Of Axle Housing

Courtesy of FORD MOTOR CO.

Using the Drive Pinion Thread Protector, drive the pinion from the outer pinion bearing and remove it through the rear of the axle housing.
Using the Slide Hammer and Bushing Remover, remove and discard the drive pinion seal.

Fig 11: Removing Drive Pinion Seal
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.

Fig 12: Removing Outer Pinion Bearing Cup

Courtesy of FORD MOTOR CO.

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