Initial disassembly

WARNING: This page is about a different car, the 2014 Ford F-150. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: If the Diagnostic Chart directed the servicing of the Traction-Lok clutch packs, it is not necessary to remove the differential carrier assembly from the axle housing. Proceed to Step 7.

NOTE: If the differential ring gear backlash between teeth is greater than specification, remove the ring gear to check the differential case flange runout. Do not disassemble the differential carrier assembly.

Remove the differential carrier. Tag the differential shims and bearing cups for location. For additional information, refer to DIFFERENTIAL CARRIER .
Remove and discard the 10 differential ring gear bolts.

Fig 1: Locating Differential Ring Gear Bolts
Courtesy of FORD MOTOR CO.
NOTE: Care should be taken not to damage the differential ring gear bolt hole threads.

Insert a punch in the differential ring gear bolt holes and drive the differential ring gear off.

Fig 2: Inserting Punch In Differential Ring Gear Bolt Holes
Courtesy of FORD MOTOR CO.
If checking differential case flange runout, install the bearing cups in their original location and install the differential assembly.
1. Install the bearing caps and differential shims.
  - Rotate the differential assembly to verify the bearings have seated.
2. Install the Dial Indicator Gauge With Holding Fixture and record the differential case runout.
  
  Fig 3: Checking Differential Case Runout
  Courtesy of FORD MOTOR CO.
Final disassembly
Using the Differential Bearing Remover and Step Plate, remove the differential bearings.

Fig 4: Removing Differential Bearings
Courtesy of FORD MOTOR CO.
Remove the differential pinion shaft lock bolt and remove the differential pinion shaft.

Fig 5: Locating Differential Pinion Shaft Lock Bolt And Shaft
Courtesy of FORD MOTOR CO.
Install the Differential Gauge in a suitable vise.

Fig 6: Installing Differential Gauge In Vise
Courtesy of FORD MOTOR CO.
Install the differential case on the Differential Gauge.

Fig 7: Identifying Differential Case
Courtesy of FORD MOTOR CO.
NOTE: Apply a small amount of grease to the centering hole of the Differential Gauge.

Install the Differential Gauge step plate in the bottom differential side gear.

Fig 8: Installing Differential Gauge Step Plate
Courtesy of FORD MOTOR CO.
Install the nut in the upper differential side gear. Hold the nut in position while installing the hex screw. Tighten the hex-head screw until contact is made with the Differential Gauge step plate.

Fig 9: Installing Differential Gauge Nut In Upper Differential Side Gear
Courtesy of FORD MOTOR CO.
NOTE: The dowel bar is used to keep the nut from turning when the forcing screw is tightened.

Insert a suitable dowel bar in the hole of the nut. Tighten the forcing screw to force the differential side gears away from the differential pinion gears.

Fig 10: Inserting Dowel Bar In Differential Side Gear Nut Hole
Courtesy of FORD MOTOR CO.
NOTE: Differential pinion gear thrust washers cannot be removed independently of the differential pinion gears.

Insert the Differential Rotator in the pinion shaft bore, and turn the differential case to "walk" the differential pinion gears and differential case windows.

Fig 11: Inserting Differential Rotator In Pinion Shaft Bore
Courtesy of FORD MOTOR CO.
Remove the differential pinion gears and differential pinion gear thrust washers.

Fig 12: Locating Differential Pinion Gears And Thrust Washers
Courtesy of FORD MOTOR CO.
Remove the differential side gears and differential clutch packs with the selective shim and Belleville spring, tag them RH and LH.

Fig 13: Identifying Differential Side Gears And Differential Clutch Packs
Courtesy of FORD MOTOR CO.
NOTE: Do not use acids or solvents when cleaning the differential clutch pack or damage to the components can result. Wipe components with a clean, lint-free cloth only.

NOTE: When separating the clutch plates and clutch disc, note the sequence in which they are disassembled. They must be reassembled in the same sequence.

Separate the differential clutch disc and clutch plates for cleaning and inspection.

Fig 14: Identifying Differential Clutch Disc And Clutch Plates
Courtesy of FORD MOTOR CO.