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Home >> Ford >> 2004 >> Mustang Mach 1, Standard >> Repair and Diagnosis (Single Page) >> Drivelines & Axles >> Differentials & Drive Axles >> Rear Drive Axle/Differential - Ford 7.5" Ring Gear >> In-Vehicle Repair >> Differential Case >> Removal

Differential Case: Removal

  1. Remove the differential housing cover (4033) and drain the rear axle (4001). For additional information, refer to DIFFERENTIAL HOUSING COVER .
    2. CAUTION: Reinstall the differential pinion shaft (4211) and the bolt in the differential case (4204) after removing the axle shafts (4234).
  2. Remove the axle shafts. For additional information, refer to AXLE SHAFT .
  3. Wipe the lubricant from the internal working parts and inspect the parts for wear and damage.
  4. Rotate the differential assembly to check for roughness indicating bearing/gear damage.
    Fig 1: Rotating Differential Assembly
    G03237138Courtesy of FORD MOTOR CO.
  5. Using a suitable dial indicator and the special tool, measure and note the ring gear backface runout.
    Fig 2: Measuring Ring Gear Backface Runout
    G03237139Courtesy of FORD MOTOR CO.
    6. CAUTION: Mark the position and location of the bearing caps, as the arrows may not be visible. Always install the bearing caps in their identical locations and positions.
  6. Remove the bearing caps.
    1. Remove the bolts.
    2. Remove the bearing caps.
      Fig 3: Removing Bearing Caps
      G03237140Courtesy of FORD MOTOR CO.
    7. WARNING: Do not allow the differential assembly to fall. Failure to follow these instructions may result in personal injury and component damage.
    CAUTION: Place a wood block between the pry bar and the differential housing (4010) to protect the machined surface from damage.
    Fig 4: Removing Differential Assembly
    G03237141Courtesy of FORD MOTOR CO.
  7. Using a pry bar and a wood block, remove the differential assembly from the differential housing.
  8. Remove the 10 bolts.
    Fig 5: Removing Bolts
    G03237142Courtesy of FORD MOTOR CO.
    9. CAUTION: Do not damage the threads in the bolt holes.
    Fig 6: Inserting Punch In Bolt Holes
    G03237143Courtesy of FORD MOTOR CO.
  9. Insert a punch in the bolt holes, and drive off the ring gear.
  10. If the ring gear backface runout measurement, taken at the beginning of this procedure, did not exceed the specification, proceed to the appropriate procedure as necessary: DRIVE PINION , DIFFERENTIAL CASE AND RING GEAR , or to INSTALLATION . If the ring gear backface runout measurement, taken at the beginning of this procedure, exceeds the specification, the cause may be a warped ring gear, differential case/differential bearing damage. Proceed as follows to verify the cause of the excessive runout.
  11. Position the differential assembly, including the differential bearing cups (4222) and differential bearing shims (4067), in the differential housing. Install the bearing caps and bolts.
    Fig 7: Installing Bearing Caps And Bolts
    G03237144Courtesy of FORD MOTOR CO.
  12. Position the special tool.
    1. Rotate the differential case to verify that the differential bearings (4221) have seated correctly.
    2. Position the special tool.
      Fig 8: Positioning Special Tool
      G03237145Courtesy of FORD MOTOR CO.
  13. Measure and note the differential case runout.
    1. Rotate the differential case.
    2. Note the runout.
      • If the runout does not exceed the specification, install a new ring gear and drive pinion gear. For additional information, refer to DRIVE PINION  and to INSTALLATION .
      • If the runout exceeds the specification, the ring gear is true and the concern is due to either differential case/differential bearing damage. Proceed as follows.
        Fig 9: Measuring Differential Case Runout
        G03237146Courtesy of FORD MOTOR CO.
  14. Remove the differential assembly from the differential housing.
  15. Using the special tools, remove the differential bearings.
    Fig 10: Removing Differential Bearings
    G03237147Courtesy of FORD MOTOR CO.
  16. Using the special tool, install the new differential bearings.
    Fig 11: Installing New Differential Bearings
    G03237148Courtesy of FORD MOTOR CO.
  17. Position the differential assembly, including the differential bearing cups and differential bearing shims, in the differential housing. Install the bearing caps and bolts.
    Fig 12: Installing Bearing Caps Bolts
    G03237149Courtesy of FORD MOTOR CO.
  18. Position the special tool.
    1. Rotate the differential case to verify that the differential bearings have seated correctly.
    2. Position the special tool.
      Fig 13: Positioning Special Tool
      G03237150Courtesy of FORD MOTOR CO.
  19. Measure the differential case runout.
    • If the runout does not exceed the specification, use the new differential bearings for assembly.
    • If the runout exceeds the specification, install a new differential case. For additional information, refer to DIFFERENTIAL CASE AND RING GEAR .
      Fig 14: Measuring Differential Case Runout
      G03237151Courtesy of FORD MOTOR CO.
  20. Remove the differential assembly from the differential housing.
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