Disassembly And Assembly: Axle: Disassembly

Fig 1: Identifying Differential Components

Courtesy of FORD MOTOR CO.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
2. Remove the axle assembly. For additional information, refer to AXLE ASSEMBLY .
3. Measure and record the pinion bearing preload.
   • Using a Nm torque wrench, rotate the pinion. Measure the torque required to maintain pinion rotation.
   Fig 2: Measuring Pinion Bearing Preload Using Nm Torque Wrench

   Courtesy of FORD MOTOR CO.
4. Remove the differential housing cover bolts and the differential housing cover.
5. Remove the RH axle shaft.
   Fig 3: Removing RH Axle Shaft

   Courtesy of FORD MOTOR CO.
6. Using the special tool, remove the axle seal.
   Fig 4: Removing Axle Seal Using Special Tool

   Courtesy of FORD MOTOR CO.
7. Using the special tool, remove the axle shaft bearing.
   Fig 5: Removing Axle Shaft Bearing

   Courtesy of FORD MOTOR CO.
8. Remove the differential bearing caps.
   1. Remove the differential bearing cap bolts.
   2. Remove and identify the differential bearing caps.
      Fig 6: Removing Differential Bearing Caps

      Courtesy of FORD MOTOR CO.
9. Install the special tool.
   Fig 7: Installing Special Tool

   Courtesy of FORD MOTOR CO.
10. Install the axle assembly into the bench fixture.
    Fig 8: Installing Axle Assembly Into Bench Fixture

    Courtesy of FORD MOTOR CO.
11. Install the special tools.
    Fig 9: Installing Special Tools

    Courtesy of FORD MOTOR CO.
CAUTION: Overspreading can damage the differential housing.
12. Spread the differential housing to the specification.
    1. Adjust the special tool to zero.
    2. Tighten the differential carrier spreader screw.
    3. Remove the dial indicator.
       Fig 10: Spread Differential Housing To Specification

       Courtesy of FORD MOTOR CO.
CAUTION: Use wood blocks to avoid damaging the differential housing.
Fig 11: Remove Differential Assembly From Housing
Courtesy of FORD MOTOR CO.
13. Remove the differential assembly from the housing.
    1. Position the wood blocks.
    2. Push downward on the pry bars.
    3. Remove the differential assembly.
    4. Remove the special tool.
14. Remove the differential ring gear.
    1. Remove and discard the differential ring gear bolts.
    2. Using a drift that will bottom out in the differential ring gear bolt holes, separate the differential ring gear from the differential assembly.
    Fig 12: Separating Differential Ring Gear From Differential Assembly

    Courtesy of FORD MOTOR CO.
15. Assemble the special tools.
    Fig 13: Assembling Special Tools

    Courtesy of FORD MOTOR CO.
16. Position the special tool on the differential bearing.
    Fig 14: Positioning Special Tool On Differential Bearing

    Courtesy of FORD MOTOR CO.
17. Using the special tool, remove the differential bearings.
    Fig 15: Removing Differential Bearings Using Special Tool

    Courtesy of FORD MOTOR CO.
18. If necessary, disassemble the differential assembly. For additional information, refer to DIFFERENTIAL CASE .
19. Index-mark the pinion flange and the pinion gear stem.
    Fig 16: Index-Marking Pinion Flange

    Courtesy of FORD MOTOR CO.
20. Using the special tool to hold the pinion flange, remove and discard the pinion nut and washer.
    Fig 17: Removing Pinion Nut And Washer Using Special Tool

    Courtesy of FORD MOTOR CO.
21. Using the special tool, remove the pinion flange.
    Fig 18: Removing Pinion Flange Using Special Tool

    Courtesy of FORD MOTOR CO.
22. Using the special tool, remove the drive pinion oil seal.
    Fig 19: Removing Drive Pinion Oil Seal

    Courtesy of FORD MOTOR CO.
23. Inspect the pinion flange for burrs and damage. Inspect the end of the pinion flange that contacts the outer pinion bearing cone, the pinion nut counterbore and the drive pinion oil seal surface for nicks. Discard the pinion flange if damaged.
24. Press the inner pinion bearing off the pinion.
    1. Install special tool under the inner pinion bearing.
    2. Using a shop press, remove the inner pinion bearing from the pinion gear stem.
    Fig 20: Removing Inner Pinion Bearing From Pinion Gear Stem Using Shop Press

    Courtesy of FORD MOTOR CO.
25. Measure and record the thickness of the drive pinion position shim for reference during assembly.
    Fig 21: Recording Thickness Of Drive Pinion Position Shim For Reference During Assembly

    Courtesy of FORD MOTOR CO.
NOTE: To prevent it from becoming misaligned in the bore, remove the inner pinion bearing cup by tapping alternately on each side of the inner pinion bearing cup with a brass drift.
Fig 22: Removing Inner Pinion Bearing Cup
Courtesy of FORD MOTOR CO.
26. If necessary, remove the inner pinion bearing cup.
NOTE: To prevent it from becoming misaligned in the bore, remove the outer pinion bearing cup by tapping alternately on each side of the outer pinion bearing cup with a brass drift.
Fig 23: Removing Outer Pinion Bearing Cup
Courtesy of FORD MOTOR CO.
27. If necessary, remove the outer pinion bearing cup.