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 inspect the parts for wear and damage.

Fig 1: Rotating Differential Assembly

Courtesy of FORD MOTOR CO.

Rotate the differential assembly to check for roughness indicating bearing/gear damage.

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 the arrows may not be visible. Always install the bearing caps 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 differential housing to protect the machined surface or damage to the component may occur.

Using a pry bar and a wood block, remove the differential assembly from the differential 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: Do not damage the differential ring gear bolt hole threads.

NOTE: If removing the anti-lock speed sensor ring, discard it, and install a new anti-lock speed sensor ring during installation.

Insert a punch in the bolt holes and drive off the differential ring gear and, if necessary, the anti-lock speed sensor ring.
Position the differential assembly, including the differential bearing cups and differential bearing shims, in the differential housing. Install the 2 bearing caps and the 4 bolts.
- Tighten to 112 Nm (83 lb-ft).

Fig 6: Positioning Special Tool (100-002)

Courtesy of FORD MOTOR CO.

Position the special tool.
1. Rotate the differential case to verify that the differential bearings have seated correctly.
2. Position the special tool.

Fig 7: Measuring Differential Case Runout Without Ring Gear (With Specification)

Courtesy of FORD MOTOR CO.

Measure and note the differential case runout.
- If the runout does not exceed the specification, install a new differential ring gear and pinion. For additional information, refer to Differential Ring And Pinion and to Installation in this procedure.
- If the runout exceeds the specification, the differential ring gear is true and the concern is due to either differential case/differential bearing damage. Proceed as follows.
Remove the 4 bearing cap bolts, the 2 bearing caps and the differential assembly from the axle housing.

Fig 8: Removing Differential Bearings Using Special Tool

Courtesy of FORD MOTOR CO.

Using the special tools, remove the differential bearings.

Fig 9: Installing Differential Bearings

Courtesy of FORD MOTOR CO.

Using the special tool, install the new differential bearings.
1. Position the bearing.
- Using the special tool, press the bearings on the differential case.

Fig 10: Identifying Differential Bearing Cap And Differential Bearing Cap Bolts

Courtesy of FORD MOTOR CO.

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

Fig 11: Positioning Special Tool (100-002)

Courtesy of FORD MOTOR CO.

Position the special tool.
1. Rotate the differential case to verify that the differential bearings have seated correctly.
2. Position the special tool.

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

Courtesy of FORD MOTOR CO.

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 - Conventional or Differential Case and Ring Gear - Traction-Lok® .
Remove the 4 bearing cap bolts, the 2 bearing caps and the differential assembly from the axle housing.