Differential Case: Removal

WARNING: This page is about a different car, the 2007 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.

Remove the axle shafts. For additional information, refer to Axle Shaft .

NOTE: Inspect the removed lubricant for metallic particles which indicate wear or damage.

Wipe the lubricant from the internal working parts and visually inspect the parts for wear or damage.

Fig 1: Rotating Differential Assembly

Courtesy of FORD MOTOR CO.

Rotate the differential case to see if there is any roughness which would indicate damaged bearings or gears.

Fig 2: Identifying Differential Bearing Cap And Differential Bearing Cap Bolts

Courtesy of FORD MOTOR CO.

NOTE: Mark the position of the bearing caps, as arrows may not be visible. The bearing caps must be installed in their original locations and positions.

Remove the 4 bolts and the 2 bearing caps.

Fig 3: Removing Differential Carrier Assembly From Axle Housing

Courtesy of FORD MOTOR CO.

CAUTION: Place a wood block between the pry bar and the rear axle housing to protect the machined surface from damage.

Using a pry bar and wood block, pry the differential case from the rear axle housing.

Fig 4: Locating Ring Gear Bolts

Courtesy of FORD MOTOR CO.

Remove and discard the 10 ring gear bolts.

Fig 5: Removing Differential Ring Gear

Courtesy of FORD MOTOR CO.

NOTE: Care should be taken not to damage the ring bolt hole threads.

NOTE: The anti-lock speed sensor ring cannot be reused once removed.

Insert a punch in the bolt holes and drive off the ring gear and, if necessary, the anti-lock speed sensor ring.

Fig 6: Locating Bearing Caps

Courtesy of FORD MOTOR CO.

Position the differential case assembly, including the bearing cups and shims, in the rear axle housing. Install the 2 differential bearing caps and the 4 differential bearing cap bolts.
- Tighten to 112 Nm (83 lb-ft).

Fig 7: Positioning Special Tool (100-002)

Courtesy of FORD MOTOR CO.

Position the special tool.
- Rotate the differential case to make sure the differential bearings are correctly seated.
- Position the special tool.

Fig 8: Measuring Differential Case Runout Without Ring Gear (With Specification)

Courtesy of FORD MOTOR CO.

Rotate the differential case and measure the differential case runout without the ring gear.
- If runout is less than the specification, install a new ring gear and pinion.
- If runout exceeds specification, the ring gear is true and the concern is due to either a damaged differential case or differential bearings.
- Inspect the differential bearings. If the differential bearings are not damaged, install new differential case and differential bearings.

Fig 9: Removing Differential Bearings Using Special Tool

Courtesy of FORD MOTOR CO.

Remove the differential case from the rear axle housing. Using the special tools, remove the differential bearings.

Fig 10: Identifying Special Tools (205-009)

Courtesy of FORD MOTOR CO.

Using the special tool, install the new differential bearings on the differential case.

Fig 11: Locating Bearing Caps

Courtesy of FORD MOTOR CO.

Position the differential case assembly, including the bearing cups and shims in the rear axle housing.
- Tighten to 112 Nm (83 lb-ft).

Fig 12: Measuring Differential Case Runout Without Ring Gear (With Specification)

Courtesy of FORD MOTOR CO.

Measure the differential case runout without the ring gear. Check the case runout again with the new differential bearings.
- If the runout is now within 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 - Conventional or Differential Case and Ring Gear - Traction-Lok® .
Remove differential case from the rear axle housing.