Differential Case: Removal

WARNING: This page is about a different car, the 2009 Ford Pickup and 2009 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING article.
Remove the 12 differential housing cover bolts and drain the lubricant from the rear axle housing.

Fig 1: Locating Differential Housing Cover Bolts

Courtesy of FORD MOTOR CO.

Remove the differential housing cover.
Remove the axle shafts. For additional information, refer to Axle Shaft .
Wipe the lubricant from the internal working parts and visually inspect the parts for wear or damage.
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.

NOTE: There is a space between the anti-lock speed sensor ring and the ring gear for measuring ring gear back face runout.

Positioning the Dial Indicator with Holding Fixture and Clutch Housing Gauge, inspect ring gear backlash and ring gear back face runout.

Fig 3: Positioning Dial Indicator With Holding Fixture & Clutch Housing Gauge

Courtesy of FORD MOTOR CO.

NOTE: Mark the position of the bearing caps, as arrows may not be visible. The bearing caps must be installed in their identical locations and positions.

Loosen the differential case.
1. Remove the 4 bearing cap bolts.
2. Remove the 2 bearing caps.

Fig 4: Bearing Cap & Bolts

Courtesy of FORD MOTOR CO.

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 5: Prying Differential Case

Courtesy of FORD MOTOR CO.

Remove and discard the 12 ring gear bolts.

Fig 6: Differential Ring Gear Bolts

Courtesy of FORD MOTOR CO.

NOTE: Care should be taken not to damage the ring gear bolt hole threads.

NOTE: The anti-lock speed sensor ring cannot be reused once removed.

Insert a punch in the bolt holes. Drive off the ring gear and, if necessary, the anti-lock speed sensor ring.

Fig 7: Driving Off Ring Gear

Courtesy of FORD MOTOR CO.

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.
4. Tighten to 119 Nm (88 lb-ft).

Fig 8: Installing Differential Case Without Ring Gear

Courtesy of FORD MOTOR CO.

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 9: Checking Runout

Courtesy of FORD MOTOR CO.

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, Differential Carrier Bearing Retaining Ring, Bearing Tube Remover and Bearing Tube Remover Screw, remove the differential bearings.

Fig 10: Assembling Special Tools

Courtesy of FORD MOTOR CO.

Using the Differential Carrier Bearing Installer, install new differential bearings on the differential case.

Fig 11: Pressing Differential Bearings On Differential Case Using Special Tool (205-D044)

Courtesy of FORD MOTOR CO.

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 12: Checking Runout

Courtesy of FORD MOTOR CO.