Differential Carrier: Removal
WARNING: This page is about a different car, the 2007 Ford F550 Super Duty and 2007 Ford F450 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION:
Do not use heat when disassembling a drive axle. To do so will destroy heat treat properties and weaken or distort axle components.
- Set the parking brake.
- Chock the wheels.
- Remove the bottom 2 carrier bolts and drain the assembly.
- Drain the axle lubricant into a suitable container.
- Disconnect the rear anti-lock brake sensor electrical connector, if equipped.
- Index-mark and remove the 4 driveshaft bolts. Position the driveshaft aside. For additional information, refer to DRIVESHAFT article.
- Loosen the pinion hex nut if drive pinion disassembly is necessary.
- Remove the axle shafts. For additional information, refer to WHEEL HUBS AND BEARINGS - FULL FLOATING AXLE - DANA article.
- Remove all but the 2 top carrier-to-axle housing bolts, noting the length and position of each bolt.
- Discard the 10 differential carrier housing bolts.
- Remove the carrier from the axle housing.
- Position a suitable jack under the carrier.
- Remove and discard the 2 remaining top carrier-to-axle housing bolts.
- Use the slots to separate the carrier approximately 25.4-50.8 mm (1-2 in) from the axle housing.
- Secure the carrier to a suitable jack and remove the carrier from the axle housing.
- Clean and dry the components as necessary.
- Inspect the gear set for pitting, scoring, wear or damage. Install new components as necessary.
- Inspect the splines for wear, cracking or distortion from twisting.
- Inspect the axle flange O-ring.
- Clean the axle housing interior, the axle and carrier housing sealing surfaces, and the carrier mounting bolt hole threads. Inspect the housing for stripped and damaged threads and bending fatigue. Repair or install new components as necessary.
- If carrier disassembly is necessary, refer to Differential Case and Ring Gear in this article.
CAUTION:
Do not strike the axle shaft flange directly with a steel hammer or sledge. This will crack and splinter the flange.
CAUTION:
Do not pry or chisel the axle shaft flange away from the hub. This will damage the sealing surface.
WARNING:
Secure the assembly to the jack. Avoid any obstructions while lowering and raising the jack. Contact with obstructions may cause the assembly to fall off the jack, which may result in serious personal injury.
CAUTION:
Alkaline cleaning solutions will damage machine surfaces. Use only emulsion cleaners or petroleum-based cleaning solvent.
CAUTION:
Use only soft, clean, lintless towels to dry the components.
CAUTION:
After drying, lightly coat the parts with rust inhibitor or clean lubricant to prevent damage from corrosion. Wrap all parts that are going to be in storage for a prolonged period in wax paper.