Differential Ring and Pinion: Removal

Remove the axle assembly. For additional information, refer to AXLE HOUSING .
Remove the differential housing cover and drain the lubricant.
Wipe the lubricant from the internal working parts and inspect the parts for wear and damage.

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 bolts that retain the differential housing cover to the differential housing.
2. Attach the special tools together with 2 3/8-inch x 1-1/2-inch bolts.
  
  Fig 1: Mounting Differential Housing To Work Bench
  Courtesy of FORD MOTOR CO.
Install the special tool by placing the spreader pins in the hole in the Housing Spreader Adapters.

Fig 2: Installing Special Tool By Placing Spreader Pins
Courtesy of FORD MOTOR CO.
Assemble the special tool.
1. Install the special tool.
2. Attach the special tool and position the tip in the Housing Spreader Adapter hole.
Fig 3: Assembling Special Tool
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 tools.
  
  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 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 case.
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.
Remove the 10 ring gear bolts.

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

CAUTION: Do not damage the ring gear bolt hole threads.

Insert a punch in the ring gear bolt holes and drive the differential ring gear off.
Using the special tools, remove the differential bearing.
- Repeat for the other side.
  
  Fig 8: Removing Differential Bearing
  Courtesy of FORD MOTOR CO.
Using the special tool, hold the pinion flange to remove and discard the pinion nut.

Fig 9: Removing Pinion Nut
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 rear axle drive pinion shaft oil slinger.
Using the special tool and a soft-faced hammer, drive the drive pinion gear out of the front pinion bearing and remove it through the rear of the differential housing.

Fig 12: Removing Drive Pinion Gear
Courtesy of FORD MOTOR CO.
Using a brass drift and a hammer, remove any damaged differential drive pinion bearing cup from the differential housing. Tap alternately on each side of the cup to prevent it from cocking in the bore.

Fig 13: Removing Damaged Differential Drive Pinion Bearing Cup From Differential Housing
Courtesy of FORD MOTOR CO.