Disassembly And Assembly: Axle: Disassembly

All Axles 

1. Remove the axle assembly from the vehicle. For additional information, refer to AXLE ASSEMBLY - AIR SUSPENSION  or AXLE ASSEMBLY - COIL SUSPENSION .
2. Remove the four bolts retaining the torque arm to the rear axle housing.
   Fig 1: Removing Bolts Retaining

   Courtesy of FORD MOTOR CO.
3. Drain the rear axle lubricant and remove the rear axle cover.
   Fig 2: Removing Rear Axle Cover

   Courtesy of FORD MOTOR CO.
4. Using the special tools, mount the differential housing to a work bench.
   Fig 3: Mounting Differential Housing To Work Bench Using Special Tool

   Courtesy of FORD MOTOR CO.
5. Using the special tool, measure and record the differential ring gear backlash between teeth in four equally spaced places around the ring gear.
   • Remove the dial indicator.
     Fig 4: Measuring And Differential Ring Gear Backlash Between Teeth

     Courtesy of FORD MOTOR CO.
CAUTION: Mark the position and location of the differential bearing caps as the arrows may not be visible. Always install the differential bearing caps in their identical location and position.
Fig 5: Removing Differential Bearing Caps
Courtesy of FORD MOTOR CO.
6. Remove the differential bearing caps.
CAUTION: Use wood blocks to avoid damaging the differential housing.
NOTE: Tag the bearing caps and shims for location as removed.
7. Remove the differential assembly.
   1. Position wood blocks at the top and bottom of the differential case.
   2. Pry the differential assembly and the differential bearing shims out of the differential housing.
      Fig 6: Prying Differential Assembly And Differential Bearing Shims Out Of Differential Housing

      Courtesy of FORD MOTOR CO.
8. Record the torque necessary to maintain rotation of the drive pinion gear through several revolutions prior to removing the drive pinion flange.
   Fig 7: Removing Drive Pinion Flange

   Courtesy of FORD MOTOR CO.
CAUTION: After removing the drive pinion nut, discard it. Use a new nut for installation.
Fig 8: Removing Drive Pinion Nut Using Special Tool
Courtesy of FORD MOTOR CO.
9. Using the special tool, remove the drive pinion nut.
10. Index-mark the drive pinion flange and drive pinion gear stem to maintain initial balance during installation.
    Fig 9: Locating Index-Mark On Drive Pinion Flange

    Courtesy of FORD MOTOR CO.
11. Remove the drive pinion flange and the pinion seal. For additional information, refer to DRIVE PINION FLANGE AND DRIVE PINION SEAL .
12. Remove the drive pinion shaft oil slinger.
    Fig 10: Removing Drive Pinion Shaft Oil Slinger

    Courtesy of FORD MOTOR CO.
13. Using the special tool and a soft-faced hammer, drive the drive pinion gear out of the front pinion bearing and remove it through the rear of the differential housing.
    Fig 11: Driving Drive Pinion Gear Out Of Front Pinion Bearing

    Courtesy of FORD MOTOR CO.
14. Remove and discard the drive pinion collapsible spacer.
    Fig 12: Removing Drive Pinion Collapsible Spacer

    Courtesy of FORD MOTOR CO.
15. Using the special tool and a suitable press, remove the drive pinion bearing.
    Fig 13: Removing Drive Pinion Bearing Using Special Tool

    Courtesy of FORD MOTOR CO.
NOTE: Using a micrometer, measure the drive pinion bearing adjustment shim thickness. Use this measurement as a reference to compare to the shim gauge reading taken prior to installing the pinion bearing.
Fig 14: Removing Drive Pinion Bearing Adjustment Shim
Courtesy of FORD MOTOR CO.
16. Remove the drive pinion bearing adjustment shim.
17. Using the special tools, remove the outer drive pinion bearing cup, if necessary.
    Fig 15: Removing Outer Drive Pinion Bearing Cup Using Special Tool

    Courtesy of FORD MOTOR CO.
18. Using the special tools, remove the inner drive pinion bearing cup.
    Fig 16: Removing Inner Drive Pinion Bearing Cup Using Special Tool

    Courtesy of FORD MOTOR CO.
19. If the differential ring gear backlash between teeth measurement, taken at the beginning of this procedure, did not exceed the specification, proceed to Final disassembly in this procedure. If the differential ring gear backlash between teeth measurement exceeds the specification, the cause may be a warped differential ring gear, a damaged differential case, or loss of differential bearing preload. Proceed to Excessive differential ring gear backlash between teeth in this procedure to verify the cause of the excessive runout.

    Excessive Differential Ring Gear Backlash Between Teeth 

20. Remove the ring gear bolts.
    Fig 17: Removing Ring Gear Bolts

    Courtesy of FORD MOTOR CO.
CAUTION: Do not damage the bolt hole threads.
Fig 18: Inserting Punch In Bolt Holes And Drive Off Differential Ring Gear
Courtesy of FORD MOTOR CO.
21. Insert a punch in the bolt holes and drive off the differential ring gear.
NOTE: Visually inspect the differential carrier bearings and cups for discoloration or other signs of bearing failure.
NOTE: Install the differential bearing cups and shims in the same locations they were in before disassembly.
Fig 19: Installing Differential Case
Courtesy of FORD MOTOR CO.
22. Install the differential case. Rotate the differential case to seat the differential bearings.
23. Using the special tool, measure the differential case flange runout.
    1. Rotate the differential case to make sure the differential bearings are seated.
    2. Position the special tool.
    • If the runout does not exceed the specification, the cause of the original excessive runout is the differential ring gear. Remove the differential case. Discard the differential ring gear and the drive pinion gear. Proceed to Final disassembly in this procedure.
    • If the runout exceeds the specification, the differential ring gear is true and the concern is due to either differential case/differential bearing damage. Remove the differential case. Discard the differential bearings/differential case. Proceed to Final disassembly in this procedure.
    1. Remove the special tool.
       Fig 20: Measuring Differential Case Flange Runout Using Special Tool

       Courtesy of FORD MOTOR CO.

    Final Disassembly, Differential Case and Ring Gear-Traction-Lok® 

24. Remove the differential ring gear bolts.
    Fig 21: Removing Differential Ring Gear Bolts

    Courtesy of FORD MOTOR CO.
CAUTION: Do not damage the ring gear bolt hole threads.
Fig 22: Inserting Punch In Bolt Holes And Drive Differential Ring Gear Off Differential Case
Courtesy of FORD MOTOR CO.
25. Insert a punch in the bolt holes and drive the differential ring gear off the differential case.
NOTE: The differential bearings do not need to be removed to overhaul the Traction-Lok® differential. If bearing removal is required, use special tool 205-D072 and special tool 205-D019 for the differential case bearings.
Fig 23: Removing Differential Pinion Shaft Lock Bolt
Courtesy of FORD MOTOR CO.
26. Remove the differential pinion shaft lock bolt and remove the differential pinion shaft.
27. Install the special tool in a suitable vise.
    Fig 24: Installing Special Tool In Vise

    Courtesy of FORD MOTOR CO.
28. Install the differential case on the tool.
    Fig 25: Installing Differential Case On Tool

    Courtesy of FORD MOTOR CO.
NOTE: Apply a small amount of grease to the centering hole of the special tool.
Fig 26: Installing Special Tool In Bottom Side Gear Bore
Courtesy of FORD MOTOR CO.
29. Install the special tool in the bottom side gear bore.
30. Install the nut in the upper differential side gear. Hold the nut in position while installing the hex screw. Tighten the hex nut until contact is made with the step plate.
    Fig 27: Installing Nut In Upper Differential Side Gear

    Courtesy of FORD MOTOR CO.
NOTE: The dowel bar is used to keep the nut from turning when the forcing screw is tightened.
Fig 28: Tightening Forcing Screw To Force Differential Side Gear
Courtesy of FORD MOTOR CO.
31. Insert a suitable dowel bar in the hole of the nut. Tighten the forcing screw to force the differential side gear away from the differential pinion gears.
32. Insert the special tool in the pinion shaft bore and turn the differential case to move the differential pin gears and thrust washers to the differential case opening.
    Fig 29: Inserting Special Tool In Pinion Shaft Bore

    Courtesy of FORD MOTOR CO.
33. Remove the differential pinion gears and differential pinion gear thrust washers.
    Fig 30: Removing Differential Pinion Gears And Differential Pinion Gear Thrust Washers

    Courtesy of FORD MOTOR CO.
34. Remove the differential side gears and differential clutch packs. Tag the gears, clutch packs and shims for location.
    Fig 31: Removing Differential Side Gears And Differential Clutch Packs

    Courtesy of FORD MOTOR CO.
CAUTION: When separating the clutch plates and clutch discs, note the sequence in which they are disassembled. They must be reassembled in the same sequence.
CAUTION: Do not use acids or solvents to clean the differential clutch components. Use a clean, lint-free cloth only.
Fig 32: View Of Differential Clutch Components
Courtesy of FORD MOTOR CO.
35. Separate the differential clutch packs for cleaning and inspection.

    Final Disassembly, Differential Case and Ring Gear-Conventional 

36. Remove the differential ring gear bolts.
    Fig 33: Removing Differential Ring Gear Bolts

    Courtesy of FORD MOTOR CO.
CAUTION: Do not damage the ring gear bolt hole threads.
Fig 34: Driving Off Differential Ring Gear
Courtesy of FORD MOTOR CO.
37. Insert a punch in the bolt holes and drive off the differential ring gear.
38. Using the special tools, remove the differential bearing.

• Repeat for the other side.
  Fig 35: Removing Differential Bearing Using Special Tool

  Courtesy of FORD MOTOR CO.