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Home >> Ford >> 2009 >> Flex Limited, FWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 870 (Front Drive Axle/Differential - DANA 35) >> Removal And Installation >> Differential Ring And Pinion >> Removal

Differential Ring And Pinion: 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.
CAUTION: Many components and surfaces in the axle are precision machined. Careful handling during disassembly, cleaning, inspection and assembly will prevent unnecessary damage to machined surfaces.
  1. Remove the front drive axle assembly from the vehicle. For additional information, refer to Axle Assembly .
    • Remove the front axle damper from the axle to frame bracket, if so equipped.
    2. Fig 1: Attaching Axle Assembly To Special Tool
    GF0009821Courtesy of FORD MOTOR CO.
  2. Attach the axle assembly to the special tool.
    3. Fig 2: Identifying Differential Housing Cover & Bolts
    GF0009822Courtesy of FORD MOTOR CO.
  3. Remove the differential housing cover.
    1. Remove the bolts.
    2. Remove the differential housing cover.
  4. Drain the axle lubricant from the differential housing.
    5. Fig 3: Removing Axle Shaft Using Jerking Motion
    GF0009823Courtesy of FORD MOTOR CO.
  5. Using a jerking motion, remove the axle shaft.
    6. Fig 4: Locating Differential Bearing Caps And Bolts
    GF0009824Courtesy of FORD MOTOR CO.
    CAUTION: The matched numbers or letters stamped on both of the differential bearing caps and the differential housing must correspond during assembly.
  6. Remove the differential bearing caps.
    1. Remove the bolts.
    2. Remove the differential bearing caps.
    7. Fig 5: Installing Special Tool (205-356)
    GF0009825Courtesy of FORD MOTOR CO.
    CAUTION: The Housing Spreader Adapter bolts have a minimum thread engagement as specified.
  7. Install the special tool.
    8. Fig 6: Installing Special Tools (100-002), (205-001) & (308-021)
    GF0009826Courtesy of FORD MOTOR CO.
  8. Install the special tools.
    • Position the Clutch Housing Alignment Adapter needle in the Housing Spreader Adapter hole.
    9. Fig 7: Locating Dial Indicator, Differential Carrier Spreader Screw And Special Tool
    GF0009827Courtesy of FORD MOTOR CO.
    CAUTION: Over spreading can damage the differential housing.
  9. Spread the differential housing to the specification.
    1. Adjust the special tool to zero.
    2. Tighten the Differential Carrier Spreader screw to spread the differential housing to the specification.
    3. Remove the Dial Indicator with Brackets and the Clutch Housing Alignment Adapter.
    10. Fig 8: Removing Differential Assembly From Axle Housing
    G03912955Courtesy of FORD MOTOR CO.
    CAUTION: Use wood blocks to avoid damaging the differential housing.
  10. Remove the differential assembly from the differential housing.
    1. Position the wood blocks.
    2. Push downward on the pry bars.
    3. Remove the differential assembly.
    4. Remove the special tool.
    11. Fig 9: Identifying Differential Ring Gear Bolts
    GF0003217Courtesy of FORD MOTOR CO.
  11. Remove the differential ring gear bolts and the differential ring gear.
    • Use a drift punch to separate the differential ring gear from the differential case.
    12. Fig 10: Assembling Special Tool (205-D036)
    GF0009828Courtesy of FORD MOTOR CO.
  12. Assemble the special tool.
    13. Fig 11: Identifying Special Tool (205-D036) On Differential Bearing
    GF0009829Courtesy of FORD MOTOR CO.
  13. Position the special tool on the differential bearing.
    14. Fig 12: Removing Differential Bearings Using Special Tool (205-D036)
    GF0009830Courtesy of FORD MOTOR CO.
  14. Using the special tool, remove the differential bearings.
    15. Fig 13: Using Special Tool (205-126) To Hold Pinion Flange While Tightening Pinion Nut
    GF0009801Courtesy of FORD MOTOR CO.
  15. Use the special tool to hold the flange while removing the nut.
    16. Fig 14: Removing Pinion Flange Using Special Tool (205-D072)
    GF0009796Courtesy of FORD MOTOR CO.
  16. Using the special tool, remove the pinion flange.
    17. Fig 15: Removing Pinion From Differential Housing
    GF0009831Courtesy of FORD MOTOR CO.
    WARNING: The gear teeth have sharp edges. Handle the gear with care to avoid personal injury.
    CAUTION: Never use a metal hammer on the pinion. Use a soft mallet to drive the pinion out of the differential housing.
  17. Using a soft-face hammer, remove the pinion from the differential housing.
    1. Hold the pinion inside the differential housing.
    2. Use a soft-face hammer to remove the pinion from the differential housing.
    18. Fig 16: Removing Pinion Seal Using Special Tool (307-309)
    GF0009797Courtesy of FORD MOTOR CO.
  18. Using the special tool and a suitable impact slide hammer, remove the pinion seal.
    19. Fig 17: Identifying Outer Drive Pinion Bearing And Drive Pinion Shaft Oil Slinger
    GF0000839Courtesy of FORD MOTOR CO.
  19. Remove the front axle drive pinion shaft oil slinger and the differential pinion bearing.
    20. Fig 18: Locating Outer Differential Drive Pinion Bearing Cup
    GF0009832Courtesy of FORD MOTOR CO.
  20. Remove the outer differential drive pinion bearing cup by tapping alternately on each side of the cup to prevent it from cocking in the bore.
    21. Fig 19: Locating Inner Differential Drive Pinion Bearing Cup
    GF0009833Courtesy of FORD MOTOR CO.
  21. Remove the inner differential drive pinion bearing cup by tapping alternately on each side of the cup to prevent it from cocking in the bore.
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