Disassembly And Assembly: Axle: Disassembly

Remove the axle assembly. Refer to AXLE ASSEMBLY in this article..
Remove the 10 bolts and the differential housing cover.
- Drain the fluid.
- Remove the bolts.
- Remove the differential housing cover.
  
  Fig 1: Installing Differential Housing Cover
  Courtesy of FORD MOTOR CO.
NOTE: The fixture mounting bolts must have the minimum specified thread engagement in the carrier or damage to the component may occur.
Install the Transmission Holding Fixture.

Fig 2: Installing Transmission Holding Fixture
Courtesy of FORD MOTOR CO.
Using the Transmission Fluid Pump Remover and Slide Hammer, remove the intermediate shaft.

Fig 3: Removing Intermediate Shaft
Courtesy of FORD MOTOR CO.
Remove the 4 bolts and the axle housing tube.

Fig 4: Removing Axle Housing Tube
Courtesy of FORD MOTOR CO.
NOTE: The housing spreader adapter bolts must have the minimum specified thread engagement in the carrier or damage to the component may occur.
Install the Differential Housing Spreader Plate and Adapter for Differential Housing Spreader.

Fig 5: Installing Adapter For Differential Housing Spreader And Differential Housing Spreader Plate
Courtesy of FORD MOTOR CO.
Position the Differential Carrier Spreader on the spreader adapters.

Fig 6: Positioning Differential Carrier Spreader On Spreader Adapters
Courtesy of FORD MOTOR CO.
Install the Dial Indicator Gauge with Holding Fixture and Clutch Holding Gauge.
- Position the adapter tip in the spreader adapter hole.
  
  Fig 7: Installing Dial Indicator Gauge With Holding Fixture
  Courtesy of FORD MOTOR CO.
NOTE:Overspreading may damage the axle housing.
Spread the axle housing to the specification.
1. Adjust the Dial Indicator Gauge to zero.
2. Tighten the housing spreader screw to spread the axle housing to the specification.
3. Remove the Dial Indicator Gauge with Holding Fixture.
  
  Fig 8: Removing Dial Indicator Gauge With Holding Fixture
  Courtesy of FORD MOTOR CO.
NOTE: Mark the differential bearing caps Top or Bottom and LH or RH appropriately before removing them. Always install the bearing caps in their original place and position.
Mark and remove the 2 differential bearing caps.
1. Remove the bolts.
2. Remove the differential bearing caps.
  
  Fig 9: Identifying Differential Bearing Caps And Bolts
  Courtesy of FORD MOTOR CO.
NOTE: Use wood blocks to avoid axle housing damage.
Remove the differential assembly from the axle housing.
1. Position the wood blocks.
2. Position and push down on the 2 pry bars.
3. Remove the differential assembly.
4. Remove the Differential Carrier Spreader.
  
  Fig 10: Removing Differential Assembly From Differential Housing
  Courtesy of FORD MOTOR CO.
Index-mark the axle U-joint flange to the pinion stem.

Fig 11: Locating Index-Mark On Axle U-Joint Flange To Pinion Stem
Courtesy of FORD MOTOR CO.
Install the Drive Pinion Flange Holding Fixture and loosen, but do not remove, the pinion nut.

Fig 12: Installing Drive Pinion Flange Holding Fixture And Pinion Nut
Courtesy of FORD MOTOR CO.
With the pinion nut still engaged by a few threads, use the 2 Jaw Puller to separate the axle U-joint flange from the pinion gear.

Fig 13: Identifying Axle U-Joint Flange And Pinion Gear
Courtesy of FORD MOTOR CO.
Remove the nut and the flange.
Using the Drive Pinion Thread Protector and a soft hammer, remove the pinion gear.

Fig 14: Removing Differential Pinion Gear Using Special Tool
Courtesy of FORD MOTOR CO.
Discard the drive pinion collapsible spacer.

Fig 15: Locating Drive Pinion Collapsible Spacer
Courtesy of FORD MOTOR CO.
NOTE: Do not damage the carrier housing while removing the pinion seal.
Remove the pinion seal and slinger.
- Pry up on the seal flange. Install gripping pliers, and strike with a hammer to remove the seal.
  
  Fig 16: Removing Drive Pinion Oil Seal
  Courtesy of FORD MOTOR CO.
Remove the outer pinion bearing.
Using the Bearing Cup Remover and Slide Hammer, remove the inner pinion bearing cup.

Fig 17: Removing Inner Drive Pinion Bearing Cup Using Special Tools
Courtesy of FORD MOTOR CO.
NOTE: The pinion bearing oil baffle aids in bearing lubrication. Normally, it is not necessary to remove the baffle.
If necessary, remove the pinion bearing oil baffle.

Fig 18: Locating Pinion Bearing Oil Baffle
Courtesy of FORD MOTOR CO.
Remove the outer pinion bearing cup by tapping alternately on each side to prevent the cup from cocking.

Fig 19: Locating Outer Pinion Bearing Cup
Courtesy of FORD MOTOR CO.
Using the Bearing Remover and a suitable press, remove the pinion bearing.

Fig 20: Removing Pinion Bearing
Courtesy of FORD MOTOR CO.
NOTE: A drive pinion bearing adjustment shim sits under the pinion bearing. Use a micrometer to measure the shim thickness. Record the measurement for comparison to the shim gauge reading taken prior to installing the pinion bearing.
Remove and measure the drive pinion bearing adjustment shim.

Fig 21: Locating Drive Pinion Bearing Adjustment Shim
Courtesy of FORD MOTOR CO.
NOTE: Use a drift punch to separate the ring gear from the differential case.
Remove and discard the 10 bolts and remove the ring gear.

Fig 22: Removing Differential Ring Gear Bolts And Differential Ring Gear
Courtesy of FORD MOTOR CO.
Using the 2 Jaw Puller and Step Plate, remove the differential bearings.

Fig 23: Removing Differential Bearings
Courtesy of FORD MOTOR CO.