Differential Case: Removal

WARNING: This page is about a different car, the 2009 Mercury Grand Marquis and 2009 Ford Crown Victoria. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: If equipped with fire suppression system, refer to FIRE SUPPRESSION SYSTEM article for Important Safety Warnings. Failure to follow this instruction may result in serious personal injury.

Remove the axle shafts. For additional information, refer to Axle Shaft .
Wipe the lubricant from the internal working parts and inspect the parts for wear and damage.
Rotate the differential assembly to check for roughness indicating bearing/gear damage.
Using a suitable dial indicator and the special tool, measure and record the differential ring gear backlash between the teeth in 4 opposing places.

Fig 1: Checking Differential Ring Gear Backlash (With Specifications)

Courtesy of FORD MOTOR CO.

NOTE: Mark the position of the differential bearing caps, as the arrows may not be visible. Always install the bearing caps in their original locations and positions.

Remove the 2 differential bearing caps.
1. Remove the 4 bolts.
2. Remove the differential bearing caps.

Fig 2: Differential Bearing Caps & Bolts

Courtesy of FORD MOTOR CO.

CAUTION: Do not allow the differential assembly to fall or component damage may occur.

CAUTION: Place a wood block between the pry bar and the differential housing to protect the machined surface from damage.

Using a pry bar and a wood block, remove the differential assembly from the differential housing.

Fig 3: Removing Differential Carrier Assembly From Axle Housing

Courtesy of FORD MOTOR CO.

Remove the 10 differential ring gear bolts.

Fig 4: Differential Ring Gear Bolts

Courtesy of FORD MOTOR CO.

NOTE: Do not damage the differential ring gear bolt hole threads.

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

Fig 5: Removing Differential Ring Gear

Courtesy of FORD MOTOR CO.

If the differential ring gear backlash variation between teeth measurement, taken at the beginning of this procedure, exceeded the specification, the cause may be a warped differential ring gear or differential case/differential bearing damage. Proceed as follows to verify the cause of the excessive backlash.

NOTE: Visually inspect the differential bearing cups and cones for discoloration indicating bearing overheating or failure.

Position the differential assembly, including the differential bearing cups and differential bearing shims as removed, in the differential housing. Install the 2 differential bearing caps and the 4 bolts.
- Tighten to 114 Nm (84 lb-ft).

Fig 6: Identifying Differential Bearing Cap And Differential Bearing Cap Bolts

Courtesy of FORD MOTOR CO.

Install the special tool.
1. Rotate the differential case to verify that the differential bearings have seated correctly.
2. Position the special tool.
3. Make sure there is no differential case end play.

Fig 7: Checking Differential Case Runout

Courtesy of FORD MOTOR CO.

Measure and note the differential case runout.
1. Install the differential shims and bearing caps.
  - Rotate the differential to seat the differential bearings.
2. Install the special tools and record the case runout. Rotate the differential case.
  - If the runout does not exceed the specification, install a new differential ring gear and pinion. For additional information, refer to Differential Ring And Pinion .
  - If the runout exceeds the specification, the concern is due to differential case/differential bearing damage. Install a new differential case. For additional information, refer to Differential Case and Ring Gear - Conventional or Differential Case and Ring Gear - Traction-Lok® .

Fig 8: Checking Differential Case Runout

Courtesy of FORD MOTOR CO.

Using the special tools, remove the differential bearings.

Fig 9: Removing Differential Bearing Using Special Tools

Courtesy of FORD MOTOR CO.