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Disassembly And Assembly: Axle: Disassembly

WARNING: This page is about a different car, the 2012 Ford Pickup, 2012 Ford F550 Super Duty, 2012 Ford F450 Super Duty, and 2012 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the axle shafts and seals. For additional information, refer to Axle Shaft Seal .
    2. NOTE: Index-mark the driveshaft to the pinion flange to maintain correct driveline balance.
    Fig 1: Locating Driveshaft Flange Bolts
    G07968071Courtesy of FORD MOTOR CO.
  2. Remove and discard the 4 driveshaft flange bolts and 2 retainers. Position the driveshaft aside.
  3. Remove the cotter pin, retainer cap and the RH outer tie-rod end nut.
    • Discard the cotter pin.
  4. Using the C-Frame and Screw, disconnect the RH tie-rod and the drag link. Position the drag link aside.
    Fig 2: Identifying Tie-Rod End
    G06776349Courtesy of FORD MOTOR CO.
  5. Remove the 10 bolts and the differential housing cover. Drain the lubricant.
    • Clean the gasket material from the differential housing and the differential housing cover.
    6. NOTE: Prior to removal, note the stamped mating letters positioning on the bearing caps and the differential housing for correct reassembly.
    Fig 3: Locating Mating Letters Position On Bearing Caps And Differential Housing
    G07968201Courtesy of FORD MOTOR CO.
  6. Remove the 4 bearing cap bolts and the 2 bearing caps.
    7. NOTE: Do not spread the differential housing more than specified or damage to the housing may occur.
    NOTE: Install the C-clamp at the 12 o'clock and 6 o'clock positions to allow the horizontal spread of the housing. Use a safety strap to restrain the C-clamp from rotation.
    NOTE: Use a C-clamp with a minimum 15-in opening and a 16, 250 pound load limit.
    Fig 4: Removing Dial Indicator Gauge
    G06777481Courtesy of FORD MOTOR CO.
  7. Using a C-clamp, the Dial Indicator Gauge with Holding Fixture and the Clutch Housing Gauge, spread the differential housing 0.38 mm (0.015 in).
    • Remove the Dial Indicator Gauge after spreading the differential housing.
  8. Using a pry bar, remove the differential with the bearing cups.
    • Remove the C-clamp after removing the differential.
  9. Measure the pinion bearing torque preload. Record the reading.
    • Rotate the pinion with a Nm (lb-in) torque wrench. Record the torque necessary to maintain rotation of the pinion through several revolutions.
    Fig 5: Checking Frequent Pinion Bearing Torque Preload
    G07968054Courtesy of FORD MOTOR CO.
  10. Using the Drive Pinion Flange Holding Fixture to prevent the flange from turning, remove and discard the pinion nut and washer.
    Fig 6: Locating Flange Nut And Washer
    G06777398Courtesy of FORD MOTOR CO.
  11. Using the Drive Pinion Flange Remover, remove the flange.
    Fig 7: Locating Flange
    G06777399Courtesy of FORD MOTOR CO.
    12. NOTE: Do not damage the pinion, the bearings or the cup.
    Fig 8: Removing Pinion Through Rear Of Differential Housing
    G07968160Courtesy of FORD MOTOR CO.
  12. Remove the pinion.
    • Using a soft-faced hammer, tap the pinion through the outer bearing. Remove the pinion through the rear of the differential housing.
  13. Using the Slide Hammer and Bushing Remover, remove and discard the pinion seal.
    Fig 9: Removing Drive Pinion Seal
    G06142593Courtesy of FORD MOTOR CO.
  14. Remove the oil slinger and the differential pinion bearing.
    Fig 10: Locating Differential Pinion Bearing
    G07968102Courtesy of FORD MOTOR CO.
  15. Using a suitable tool, remove the outer pinion bearing cup, the inner pinion bearing cup and the oil baffle.
    • Use the Handle and the Bearing Cup Remover/Installer (205-D051) to remove the inner pinion bearing cup.
    • Use the Handle and the Bearing Cup Remover/Installer (205-D054) to remove the outer pinion bearing cup.
  16. Using a suitable tool, drive the inner axle shaft oil seals out of the differential housing from the axle tubes. Discard the seals.
    Fig 11: Locating Inner Axle Shaft Oil Seals
    G07968242Courtesy of FORD MOTOR CO.
  17. Remove and discard the collapsible spacer.
    Fig 12: Locating Collapsible Spacer
    G07968122Courtesy of FORD MOTOR CO.
  18. Using the Drive Pinion/Differential Carrier Puller, remove the differential pinion bearing.
    Fig 13: Removing Differential Pinion Bearing
    G06777512Courtesy of FORD MOTOR CO.
    19. NOTE: Discard the drive pinion position shim if bent or nicked. Measure and record the shim thickness if discarding the shim.
  19. Remove the drive pinion position shim.
    20. NOTE: Always use new solvent when cleaning the bearings.
    NOTE: Do not spin dry the bearings with compressed air.
    NOTE: Oil the bearings immediately, to prevent rusting.
  20. Carry out the following inspection:
    • Thoroughly clean all parts, including the differential housing and inside of the differential case.
    • Inspect all parts for damage.
    • Discard the complete differential if excessive wear is visible on all parts.
    • Discard both differential pinion gears and both differential side gears if any one of these gears are worn/damaged.
    • Inspect the flange lugs for damage. The end of the flange that contacts the bearing cone as well as the nut counterbore and the seal contact area must be smooth and free of nicks.
    • Verify that the differential and pinion bearing bores are smooth. Remove any nicks/burrs from the mounting surfaces of the differential housing.
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