Differential Case and Ring Gear: Disassembly

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.

All axles

Using the special tool, mount the carrier housing.

Fig 1: Identifying Special Tool
Courtesy of FORD MOTOR CO.

CAUTION: If reusing the differential ring gear and pinion, measure and record the backlash before disassembly. Assembling the differential ring gear and pinion to the recorded backlash will match the established wear patterns. Hand-rolled patterns will cover less area than the established patterns.

Measure and record the differential ring gear and pinion backlash.
- Check the backlash in 4 equally spaced positions around the differential ring gear.
- The tooth contact pattern can move only by adjusting backlash. The tooth contact pattern can move only in the direction of heel-to-toe and toe-to-heel. Depth of the tooth contact pattern is not adjustable. Contact Spicer Service at 1-800-666-8688 for assistance if you are unable to establish an acceptable tooth contact pattern within the limits of backlash.
  
  Fig 2: Measuring Differential Ring Gear Backlash
  Courtesy of FORD MOTOR CO.
Remove the rear anti-lock brake sensor.

Fig 3: Locating Rear Anti-Lock Brake Sensor
Courtesy of FORD MOTOR CO.
Remove the adjusting ring cotter pins.

Fig 4: Locating Adjusting Ring Cotter Pins
Courtesy of FORD MOTOR CO.
Loosen, but do not remove, the 6 bearing cap bolts.

Fig 5: Locating Bearing Cap Bolts
Courtesy of FORD MOTOR CO.
Relieve the bearing preload.
- Loosen each differential bearing adjusting ring.
  
  Fig 6: Loosening Differential Bearing Adjusting Ring
  Courtesy of FORD MOTOR CO.
Remove the bearing cap bolts, bearing caps and adjusting rings.

Fig 7: Locating Bearing Cap Bolts
Courtesy of FORD MOTOR CO.
Carefully lift the differential subassembly out of the carrier.
Inspect the differential side bearing surfaces and differential side bearing cups for pitting, wear or overheating. Install new components as necessary

Fig 8: Locating Differential Side Bearing Surfaces
Courtesy of FORD MOTOR CO.
Using the special tools, remove the differential side bearings if worn or damaged.

Fig 9: Removing Differential Side Bearings
Courtesy of FORD MOTOR CO.
Remove the 12 ring gear bolts.

Fig 10: Identifying Ring Gear Bolts
Courtesy of FORD MOTOR CO.
Place the differential assembly in a suitable press supported on the ring gear.

WARNING: The differential case will fall after separation. Support the case so it will not result in damage to the component or equipment. Failure to follow these instructions can result in personal injury.

CAUTION: It should not require more than 3 tons of press load to separate the ring gear from the differential case.

NOTE: It may be necessary to press in more than one position to free the ring gear from the case.

Fig 11: Removing Ring Gear From Differential Case

Courtesy of FORD MOTOR CO.

The press arbor will push on the differential ring gear bolt to separate the ring gear half of the differential from the cross shaft half of the assembly.

CAUTION: Discard the anti-lock speed sensor ring if separating it from the ring gear side case half.

Fig 12: Identifying Anti-Lock Speed Sensor Ring

Courtesy of FORD MOTOR CO.

If necessary, remove the anti-lock speed sensor ring.

CAUTION: Alkaline cleaning solutions will damage machine surfaces. Use only emulsion cleaners or petroleum-based cleaning solvents.

CAUTION: Use soft, clean, lintless towels to dry the components.

CAUTION: Never spin-dry bearings with compressed air. This will damage the mating surfaces due to a lack of lubrication.

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.

NOTE: For Truetrac® differentials, submerge the entire differential assembly in a suitable solvent to wash away contaminants from within the housing.

Clean and dry the components.
The Truetrac® differential assembly is non-repairable. Discard the entire assembly if it is worn or damaged.

Fig 13: Locating Bolts
Courtesy of FORD MOTOR CO.

S110 axles

With a conventional differential, lift out the side gear.

Fig 14: Identifying Outer Side Gear
Courtesy of FORD MOTOR CO.
Remove the differential pinion cross shaft lock pin.

Fig 15: Locating Differential Pinion Cross Shaft Lock Pin
Courtesy of FORD MOTOR CO.

CAUTION: Discard all gears in sets if one or more sustains wear or damage.

Fig 16: Identifying Pinion Cross Shaft

Courtesy of FORD MOTOR CO.

Remove the pinion cross shaft.
Remove the inner side gear and thrust washer.

Fig 17: Identifying Inner Side Gear And Thrust Washer
Courtesy of FORD MOTOR CO.
Refer to DRIVE PINION in this section if disassembly is necessary.

S130 axles

Remove the outer side gear.

Fig 18: Removing Outer Side Gear
Courtesy of FORD MOTOR CO.
Remove the differential shaft locking pins by turning the differential case opening facing down. Using a hammer, lightly tap the side of the case to free the locking pins.

Fig 19: Tapping Side Of Case To Free Locking Pins
Courtesy of FORD MOTOR CO.
Remove the locking pins.

Fig 20: Removing Locking Pins
Courtesy of FORD MOTOR CO.
Remove the halfshaft pinion shafts, pinions and washers.
1. Remove the halfshaft.
2. Remove the pinion and washer.
  
  Fig 21: Removing Halfshaft Pinion Shafts, Pinions And Washers
  Courtesy of FORD MOTOR CO.
Remove the full shaft pinion shaft, pinions and washers.

Fig 22: Identifying Pinion Shaft, Pinions And Washers
Courtesy of FORD MOTOR CO.
Remove the inner side gear and thrust washer.

Fig 23: Identifying Inner Side Gear And Thrust Washer
Courtesy of FORD MOTOR CO.