Differential Case: Removal

All vehicles 

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
2. Remove the 12 differential housing cover bolts and drain the lubricant from the rear axle housing.
   Fig 1: Locating Differential Housing Cover Mounting Bolts

   Courtesy of FORD MOTOR CO.
3. Remove the differential housing cover.
4. Remove the axle shafts. For additional information, refer to WHEEL HUBS AND BEARINGS - FULL FLOATING AXLE - FORD .
5. Wipe the lubricant from the internal working parts and visually inspect the parts for wear or damage.
6. Rotate the differential case to see if there is any roughness which would indicate damaged bearings or gears.
   Fig 2: Rotating Differential Case

   Courtesy of FORD MOTOR CO.
7. Positioning the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, inspect ring gear backlash.
   Fig 3: Measuring Ring Gear Backlash Using Dial Indicator Gauge

   Courtesy of FORD MOTOR CO.
8. NOTE: Index-mark the position of the differential bearing caps, as arrows may not be visible. The differential bearing caps must be installed in their original locations and positions.

   Remove the 4 differential bearing cap bolts and the 2 differential bearing caps.

   Fig 4: Locating Differential Bearing Cap Bolts

   Courtesy of FORD MOTOR CO.

   ELD equipped vehicles 

9. Disconnect the ELD electrical connector and remove the bolt that holds the connector adapter to the housing.
   Fig 5: Locating ELD Connector Mounting Bolts

   Courtesy of FORD MOTOR CO.
10. Pull the connector adapter out and disconnect the ELD coil electrical connector from the connector adapter. Discard the adapter.
    Fig 6: Locating ELD Coil Electrical Connector Adapter

    Courtesy of FORD MOTOR CO.

    All vehicles 

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

    Use the pry bar and the wood block to remove the differential case from the rear axle housing.

    Fig 7: Removing Differential Case From Rear Axle Housing

    Courtesy of FORD MOTOR CO.
12. Remove and discard the 12 ring gear bolts.
    Fig 8: Locating Differential Ring Gear Bolts

    Courtesy of FORD MOTOR CO.
13. NOTE: Care should be taken not to damage the ring gear bolt hole threads.

    Insert a punch in the bolt holes. Drive off the ring gear.

    Fig 9: Removing Ring Gear

    Courtesy of FORD MOTOR CO.
14. Install the differential case without the ring gear.
    1. Position the differential case assembly, including bearing clips and shims, in the housing.
    2. Install the 2 differential bearing caps.
    3. Install the 4 differential bearing cap bolts.
       • Tighten to 118 Nm (87 lb-ft).
         Fig 10: Identifying Differential Case Assembly, Differential Bearing Cap And Bolts

         Courtesy of FORD MOTOR CO.
15. NOTE: Rotate the differential case to make sure the differential bearings are correctly seated.
    NOTE: If runout is within 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 damaged, install new differential bearings.

    Measure the differential case runout by rotating the differential case.

    Fig 11: Measuring Differential Case Runout

    Courtesy of FORD MOTOR CO.
16. Remove the differential case from the rear axle housing and using the Differential Carrier Bearing Step Plate, Differential Carrier Bearing Retaining Ring, Differential Carrier Bearing Collets, Bearing Tube Remover and Bearing Tube Remover Screw, remove the differential bearings.
    Fig 12: Removing Differential Case From Rear Axle Housing Using Special Tools

    Courtesy of FORD MOTOR CO.
17. Using the Differential Carrier Bearing Installer, install new differential bearings on the differential case.
    Fig 13: Installing Differential Bearings Using Differential Carrier Bearing Installer

    Courtesy of FORD MOTOR CO.
18. 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 the specification shown, use the new differential bearings for assembly. If the runout is still excessive, the differential case is damaged and a new differential case must be installed.
      Fig 14: Measuring Differential Case Runout

      Courtesy of FORD MOTOR CO.