Differential Bearings: Removal

Remove the rear axle assembly. For additional information, refer to AXLE HOUSING .
Remove the differential housing cover and drain the lubricant.

CAUTION: Do not damage the aluminum differential housing while carrying out these procedures.

Using the special tools, mount the differential housing to a work bench.
1. Attach the special tools to the differential housing with 4 differential housing cover bolts.
2. Attach the special tools together with 2 3/8-inch x 1-1/2-inch bolts.
  
  Fig 1: Mounting Differential Housing To A Work Bench
  Courtesy of FORD MOTOR CO.

CAUTION: RH spreader set screw must not be adjusted further down than flush or the spreader rocks and damages the seal and the housing.

Fig 2: Installing Special Tool By Placing Spreader Pins

Courtesy of FORD MOTOR CO.

Install the special tool by placing the spreader pins in the hole in the housing spreader adapters.
Assemble the special tools.
1. Install the special tool.
2. Attach the special tool and position the tip in the housing spreader adapter hole.
  
  Fig 3: Assembling Special Tools
  Courtesy of FORD MOTOR CO.

CAUTION: Overspreading can damage the differential housing.

NOTE: Tighten and loosen the differential carrier spreader screw to normalize the housing spreader adapters prior to taking the final dial indicator reading.

Spread the differential housing to the specification.
1. Adjust the special tool to zero.
2. Tighten the screw until the differential housing is spread to the specification.
3. Remove the special tool.
  
  Fig 4: Spreading Differential Housing
  Courtesy of FORD MOTOR CO.

CAUTION: Mark the position and location of the differential bearing caps as the arrows may not be visible. Always install the differential bearing caps in their original locations and positions.

Remove the differential bearing caps.
1. Remove the differential bearing cap bolts.
2. Remove the differential bearing caps.
  
  Fig 5: Removing Differential Bearing Caps
  Courtesy of FORD MOTOR CO.

CAUTION: Use wood blocks to avoid damaging the differential housing.

Remove the differential assembly.
1. Position wood blocks at the top and bottom of the differential assembly.
2. Pry the differential assembly and the differential bearing shims out of the differential housing.
3. Remove the special tool.
  
  Fig 6: Removing Differential Assembly
  Courtesy of FORD MOTOR CO.
Using the special tools, remove the differential bearings.

Fig 7: Removing Differential Bearings
Courtesy of FORD MOTOR CO.
Using the special tool, hold the pinion flange to remove and discard the pinion nut.

Fig 8: Removing Pinion Nut
Courtesy of FORD MOTOR CO.
Index mark the pinion flange to the drive pinion stem.

Fig 9: Identifying Mark On Pinion Flange To Drive Pinion Stem
Courtesy of FORD MOTOR CO.
Using the special tool, remove the pinion flange.

Fig 10: Removing Pinion Flange
Courtesy of FORD MOTOR CO.
Use a screwdriver to force up the metal flange of the drive pinion oil seal. Install gripping pliers and strike with a hammer to remove the drive pinion oil seal.

Fig 11: Removing Drive Pinion Oil Seal
Courtesy of FORD MOTOR CO.
Remove the drive pinion oil seal deflector, drive pinion oil seal slinger, the outer pinion bearing and the drive pinion collapsible spacer.
Using the special tool and a soft-faced hammer, remove the differential pinion gear from the differential housing.

Fig 12: Removing Differential Pinion Gear From Differential Housing
Courtesy of FORD MOTOR CO.
Using the special tool and a press, remove the drive pinion inner bearing.
1. Position the special tool under the drive pinion inner bearing.
2. Using a press, remove the inner drive pinion bearing and shim.
  
  Fig 13: Removing Drive Pinion Inner Bearing
  Courtesy of FORD MOTOR CO.
Using a brass drift and a hammer, remove the differential drive pinion bearing cups from the differential housing. Tap alternately on each side of the cup to prevent them from cocking in the bore.

Fig 14: Removing Differential Drive Pinion Bearing Cups From Differential Housing
Courtesy of FORD MOTOR CO.