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Disassembly And Assembly: Axle: Disassembly

WARNING: This page is about a different car, the 2005 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Exploded View Of Axle
G03961134Courtesy of FORD MOTOR CO.
Fig 2: Item description Of Axle (Item 1 - 43)
G03961135Courtesy of FORD MOTOR CO.
  1. Remove the axle assembly. For additional information, refer to AXLE ASSEMBLY .
  2. Remove the differential housing cover.
    • Drain the fluid.
    • Remove the 10 differential housing cover bolts.
    • Remove the differential housing cover.
    Fig 3: Removing Differential Housing Cover
    G03928402Courtesy of FORD MOTOR CO.
    3. CAUTION: The fixture mounting bolts must have the minimum specified thread engagement in the carrier.
    Fig 4: Installing Special Tool
    G03928403Courtesy of FORD MOTOR CO.
  3. Install the special tool.
  4. Using a suitable axle shaft remover, remove the RH and LH axle shafts.
    Fig 5: Removing RH And LH Axle Shafts Using Suitable Axle Shaft Remover
    G03928405Courtesy of FORD MOTOR CO.
  5. Remove the 4 axle tube bolts and the axle tube.
    Fig 6: Removing 4 Axle Tube Bolts And Axle Tube
    G03928469Courtesy of FORD MOTOR CO.
    6. CAUTION: The housing spreader adapter bolts must have the minimum specified thread engagement in the carrier.
    Fig 7: Installing Special Tools
    G03928406Courtesy of FORD MOTOR CO.
  6. Install the special tools.
  7. Install the special tools, measure and record the differential ring gear backlash between teeth in 4 opposing places.
    1. Mount the special tool.
    2. Position the special tool.
    3. Zero the indicator.
    4. Turn the differential ring gear without turning the pinion gear. Record the measurement.
      • If the backlash between teeth exceeds the specification of 0.203-0.381 mm (0.008-0.015 in), continue with disassembly.
      • If the backlash variation between points checked exceeds the specification of 0.101 mm (0.004 in), do a differential case runout check. For additional information, refer to DIFFERENTIAL CASE RUNOUT CHECK .
    Fig 8: Installing Special Tools To Measure Differential Ring Gear Backlash Between Teeth In 4 Opposing Places
    G03961141Courtesy of FORD MOTOR CO.
  8. Position the special tool on the spreader adapters.
    Fig 9: Positioning Special Tool On Spreader Adapters
    G03928407Courtesy of FORD MOTOR CO.
  9. Install the special tools.
    • Position the adapter tip in the spreader adapter hole.
    Fig 10: Positioning Adapter Tip In Spreader Adapter Hole
    G03960874Courtesy of FORD MOTOR CO.
    10. CAUTION: Overspreading can damage the axle housing.
    Fig 11: Spreading Axle Housing To Specification
    G03960875Courtesy of FORD MOTOR CO.
  10. Spread the axle housing to the specification.
    1. Adjust the special tool to zero.
    2. Tighten the housing spreader screw to spread the axle housing to the specification.
    3. Remove the special tool.
    11. CAUTION: Mark the differential bearing caps Top or Bottom and LH or RH appropriately before removing them. Always install the differential bearing caps in their original positions.
    Fig 12: Marking Differential Bearing Caps
    G03928410Courtesy of FORD MOTOR CO.
  11. Mark and remove the differential bearing caps.
    1. Remove the 4 differential bearing cap bolts.
    2. Remove the differential bearing caps.
    12. CAUTION: Use wood blocks to avoid axle housing damage.
    Fig 13: Removing Differential Assembly From Axle Housing
    G03912955Courtesy of FORD MOTOR CO.
  12. Remove the differential assembly from the axle housing.
    1. Position the wood blocks.
    2. Position and push down on the two pry bars.
    3. Remove the differential assembly.
    4. Remove the special tool.
  13. Remove the 10 differential ring gear bolts and the differential ring gear.
    • Use a drift punch to separate the differential ring gear from the differential case.
    Fig 14: Removing 10 Differential Ring Gear Bolts And Differential Ring Gear
    G03912881Courtesy of FORD MOTOR CO.
  14. Using the special tools, remove the 2 differential bearings.
    Fig 15: Using Special Tools To Remove 2 Differential Bearings
    G03928259Courtesy of FORD MOTOR CO.
  15. If necessary, disassemble the differential assembly. For additional information, refer to DIFFERENTIAL CASE .
  16. Index mark the pinion flange to the drive pinion gear.
    Fig 16: Identifying Index-Mark On Pinion Flange And Drive Pinion Gear
    G03928220Courtesy of FORD MOTOR CO.
  17. Install the special tool and loosen, but do not remove, the pinion nut.
    • Remove the special tool.
    Fig 17: Installing Special Tool And Loosening Pinion Nut
    G03928261Courtesy of FORD MOTOR CO.
  18. With the pinion nut still engaged by a few threads, use the special tool to separate the pinion flange from the drive pinion gear.
    Fig 18: Using Special Tool To Separate Pinion Flange From Drive Pinion Gear
    G03928262Courtesy of FORD MOTOR CO.
  19. Remove the pinion nut and the pinion flange.
    20. CAUTION: Do not damage the axle housing while removing the drive pinion seal.
    Fig 19: Removing Drive Pinion Seal And Drive Pinion Oil Slinger
    G03878521Courtesy of FORD MOTOR CO.
  20. Remove the drive pinion seal and drive pinion oil slinger.
    • Pry up on the drive pinion seal flange. Install gripping pliers, and strike with a hammer to remove the drive pinion seal.
  21. Remove the outer drive pinion bearing.
  22. Using the special tool and a soft hammer, remove the drive pinion gear.
    Fig 20: Using Special Tool And Soft Hammer To Remove Drive Pinion Gear
    G03928264Courtesy of FORD MOTOR CO.
  23. Remove and discard the drive pinion collapsible spacer.
    Fig 21: Removing Drive Pinion Collapsible Spacer
    G03928265Courtesy of FORD MOTOR CO.
  24. Using the special tools, remove the inner drive pinion bearing cup.
    Fig 22: Using Special Tools To Remove Inner Drive Pinion Bearing Cup
    G03961155Courtesy of FORD MOTOR CO.
    25. NOTE: The pinion bearing oil baffle aids in bearing lubrication. Normally, it is not necessary to remove the baffle.
    Fig 23: Removing Pinion Bearing Oil Baffle
    G03928267Courtesy of FORD MOTOR CO.
  25. If necessary, remove the pinion bearing oil baffle.
  26. Remove the outer drive pinion bearing cup by tapping alternately on each side to prevent the drive pinion bearing cup from becoming misaligned.
    Fig 24: Removing Outer Drive Pinion Bearing Cup
    G03928268Courtesy of FORD MOTOR CO.
  27. Using the special tool and a suitable press, remove the inner drive pinion bearing.
    Fig 25: Using Special Tool And Suitable Press To Remove Inner Drive Pinion Bearing
    G03961158Courtesy of FORD MOTOR CO.
    28. NOTE: A drive pinion bearing adjustment shim sits under the drive pinion bearing. Use a micrometer to measure the drive pinion bearing adjustment shim thickness. Record the measurement for comparison to the drive pinion bearing adjustment shim gauge reading taken prior to installing the drive pinion bearing.
    Fig 26: Removing Drive Pinion Bearing Adjustment Shim
    G03928486Courtesy of FORD MOTOR CO.
  28. Remove and measure the drive pinion bearing adjustment shim.
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