Front Drive Axle, Disassembled View: Disassembly

WARNING: This page is about a different car, the 2013 Ford F-550 Super Duty, 2013 Ford F-450 Super Duty, 2013 Ford F-350 Super Duty, and 2013 Ford F-250 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.

Remove the axle shafts and seals. For additional information, refer to AXLE SHAFT SEAL .
NOTE: Index-mark the driveshaft to the pinion flange to maintain correct driveline balance.

Remove and discard the 4 driveshaft flange bolts and 2 retainers. Position the driveshaft aside.

Fig 1: Locating Driveshaft Flange Bolts
Courtesy of FORD MOTOR CO.
Remove the cotter pin, retainer cap and the RH outer tie-rod end nut.
- Discard the cotter pin.
Using the C-Frame and Screw, disconnect the RH tie-rod and the drag link. Position the drag link aside.

Fig 2: Disconnecting RH Tie-Rod And Drag Link Using C-Frame And Screw
Courtesy of FORD MOTOR CO.
Remove the 10 bolts and the differential housing cover. Drain the lubricant.
- Clean the gasket material from the differential housing and the differential housing cover.
NOTE: Prior to removal, note the stamped mating letters positioning on the bearing caps and the differential housing for correct reassembly.

Remove the 4 bearing cap bolts and the 2 bearing caps.

Fig 3: Locating Mating Letters Positioning On Bearing Caps And Differential Housing
Courtesy of FORD MOTOR CO.
NOTE: Do not spread the differential housing more than specified or damage to the housing may occur.

NOTE: Install the C-clamp at the 12 o'clock and 6 o'clock positions to allow the horizontal spread of the housing. Use a safety strap to restrain the C-clamp from rotation.

NOTE: Use a C-clamp with a minimum 15-in opening and a 16, 250 pound load limit.

Using a C-clamp, the Dial Indicator Gauge with Holding Fixture and the Clutch Housing Gauge, spread the differential housing 0.38 mm (0.015 in).
- Remove the Dial Indicator Gauge after spreading the differential housing.
  
  Fig 4: Seating Differential Into Differential Housing
  Courtesy of FORD MOTOR CO.
Using a pry bar, remove the differential with the bearing cups.
- Remove the C-clamp after removing the differential.
Measure the pinion bearing torque preload. Record the reading.
- Rotate the pinion with a Nm (lb-in) torque wrench. Record the torque necessary to maintain rotation of the pinion through several revolutions.
  
  Fig 5: Measuring Pinion Bearing Torque Preload
  Courtesy of FORD MOTOR CO.
Using the Drive Pinion Flange Holding Fixture to prevent the flange from turning, remove and discard the pinion nut and washer.

Fig 6: Locating Pinion Nut And Washer
Courtesy of FORD MOTOR CO.
Using the Drive Pinion Flange Remover, remove the flange.

Fig 7: Removing Flange Using Drive Pinion Flange Remover
Courtesy of FORD MOTOR CO.
NOTE: Do not damage the pinion, the bearings or the cup.

Remove the pinion.
- Using a soft-faced hammer, tap the pinion through the outer bearing. Remove the pinion through the rear of the differential housing.
  
  Fig 8: Removing Pinion Through Rear Of Differential Housing
  Courtesy of FORD MOTOR CO.
Using the Slide Hammer and Bushing Remover, remove and discard the pinion seal.

Fig 9: Removing Pinion Seal Using Slide Hammer And Bushing Remover
Courtesy of FORD MOTOR CO.
Remove the oil slinger and the differential pinion bearing.

Fig 10: Locating Differential Pinion Bearing
Courtesy of FORD MOTOR CO.
Using a suitable tool, remove the outer pinion bearing cup, the inner pinion bearing cup and the oil baffle.
- Use the Handle and the Bearing Cup Remover/Installer (205-D051) to remove the inner pinion bearing cup.
- Use the Handle and the Bearing Cup Remover/Installer (205-D054) to remove the outer pinion bearing cup.
Using a suitable tool, drive the inner axle shaft oil seals out of the differential housing from the axle tubes. Discard the seals.

Fig 11: Driving Inner Axle Shaft Oil Seals
Courtesy of FORD MOTOR CO.
Remove and discard the collapsible spacer.

Fig 12: Locating Collapsible Spacer
Courtesy of FORD MOTOR CO.
Using the Drive Pinion/Differential Carrier Puller, remove the differential pinion bearing.

Fig 13: Removing Differential Pinion Bearing
Courtesy of FORD MOTOR CO.
NOTE: Discard the drive pinion position shim if bent or nicked. Measure and record the shim thickness if discarding the shim.

Remove the drive pinion position shim.
NOTE: Always use new solvent when cleaning the bearings.

NOTE: Do not spin dry the bearings with compressed air.

NOTE: Oil the bearings immediately, to prevent rusting.

Carry out the following inspection.
- Thoroughly clean all parts, including the differential housing and inside of the differential case.
- Inspect all parts for damage.
- Discard the complete differential if excessive wear is visible on all parts.
- Discard both differential pinion gears and both differential side gears if any one of these gears are worn/damaged.
- Inspect the flange lugs for damage. The end of the flange that contacts the bearing cone as well as the nut counterbore and the seal contact area must be smooth and free of nicks.
- Verify that the differential and pinion bearing bores are smooth. Remove any nicks/burrs from the mounting surfaces of the differential housing.