Differential Carrier: Removal
WARNING: This page is about a different car, the 2006 Ford F550 Super Duty and 2006 Ford F450 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.
WARNING:
Do not use heat when disassembling a drive axle. To do so will destroy heat treat properties and weaken or distort axle components. Failure to follow these instructions may result in personal injury.
- Steam clean the axle assembly.
- Set the parking brake.
- Chock the wheels.
- Drain the axle lubricant into a suitable container.
- Remove the bottom 2 carrier bolts and drain the assembly.
- Disconnect the rear anti-lock brake sensor electrical connector, if equipped.
- Index-mark and disconnect the driveshaft, and position it aside. For additional information, refer to DRIVESHAFT .
- Loosen the pinion hex nut if drive pinion disassembly is necessary.
- Remove the axle shafts. For additional information, refer to WHEEL HUBS AND BEARINGS - FULL FLOATING AXLE - DANA .
- Remove all but the 2 top carrier-to-axle housing bolts, noting the length and position of each bolt.
- Discard the differential carrier housing bolts.
- Remove the carrier from the axle housing.
- Position a suitable jack under the carrier.
- Remove and discard the 2 remaining top carrier-to-axle housing bolts.
- Use the slots to separate the carrier approximately 25.4-50.8 mm (1-2 inches) from the axle housing.
- Secure the carrier to a suitable jack and remove the carrier from the axle housing.
- Clean and dry the components as necessary.
- Inspect the gear set for pitting, scoring, wear or damage. Install new components as necessary.
- Inspect the splines for wear, cracking or distortion from twisting.
- Inspect the axle flange O-ring.
- Clean the axle housing interior, the axle and carrier housing sealing surfaces, and the carrier mounting bolt hole threads. Inspect the housing for stripped and damaged threads and bending fatigue. Repair or install new components as necessary.
- If carrier disassembly is necessary, refer to DIFFERENTIAL CASE AND RING GEAR .
CAUTION:
Steam clean the axle prior to removal from the vehicle. Dirt is abrasive and will cause premature wear of otherwise usable parts.
WARNING:
Do not strike the axle shaft flange directly with a steel hammer or sledge. This will crack and splinter the flange. Failure to follow these instructions may result in personal injury.
CAUTION:
Do not pry or chisel the axle shaft flange away from the hub. This will damage the sealing surface.
WARNING:
Secure the carrier to the jack to prevent it from falling when removing it from the axle housing. Failure to follow these instructions may result in personal injury.
CAUTION:
Alkaline cleaning solutions will damage machine surfaces. Use only emulsion cleaners or petroleum based cleaning solvent.
CAUTION:
Use only soft, clean, lintless towels to dry the components.
CAUTION:
After drying, lightly coat the parts with rust inhibitor or clean lubricant to prevent damage from corrosion. Wrap all parts that are going to be in storage for a prolonged period in wax paper.