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Disassembly And Assembly: Axle: Disassembly

WARNING: This page is about a different variant/trim than selected.
CAUTION: Extreme care must be taken not to damage aluminum axle housing while carrying out these procedures.
  1. Using the special tool, mount the axle housing to a bench.
    Fig 1: Mount Axle Housing To A Bench
    G02743584Courtesy of FORD MOTOR CO.
    2. NOTE: RH shown; LH similar.
    Fig 2: Removing Halfshaft Seals
    G02743585Courtesy of FORD MOTOR CO.
  2. Using the special tools, remove the two halfshaft seals.
    3. NOTE: RH shown; LH similar.
    Fig 3: Removing Halfshaft Bearing Assemblies
    G02743586Courtesy of FORD MOTOR CO.
  3. Using the special tools, remove the two halfshaft bearing assemblies.
    4. CAUTION: The letters or numbers stamped on the cap and carrier must be matched upon assembly.
    Fig 4: Removing Bolts & Bearing Caps
    G02743587Courtesy of FORD MOTOR CO.
  4. Remove the bearing caps.
    1. Remove the bolts.
    2. Remove the bearing caps.
    5. CAUTION: Overspreading can damage the axle housing.
    Fig 5: Removing Differential Case
    G02743588Courtesy of FORD MOTOR CO.
  5. Using the special tools, remove the differential case.
    1. Spread the axle housing.
    2. Remove the differential case and tag the bearing cups to indicate which side of the carrier they were removed from.
  6. Remove the special tools.
    Fig 6: Removing Special Tools
    G02743589Courtesy of FORD MOTOR CO.
    7. CAUTION: Make sure the drive pinion does not fall out of the axle case when the drive pinion nut is removed.
    NOTE: The drive pinion nut is staked in the groove of the drive pinion shaft. There may be metal left in the groove that must be removed.
    Fig 7: Removing Drive Pinion Nut
    G02743590Courtesy of FORD MOTOR CO.
  7. Using the special tools, remove the drive pinion nut.
    8. WARNING: Gear teeth have sharp edges. Use care when handling the drive pinion. Failure to follow these instructions may result in personal injury.
    Fig 8: Removing Drive Pinion, Collapsible Spacer And Inner Drive Pinion Bearing
    G02743591Courtesy of FORD MOTOR CO.
  8. Remove the drive pinion, collapsible spacer and drive pinion bearings.
    1. Remove the drive pinion, collapsible spacer and inner drive pinion bearing.
    2. Remove the outer drive pinion bearing.
      • Discard the collapsible spacer.
  9. Using the special tools, remove the outer drive pinion bearing cup.
    Fig 9: Removing Outer Drive Pinion Bearing Cup
    G02743592Courtesy of FORD MOTOR CO.
    10. CAUTION: Make sure not to damage the axle housing when removing the inner drive pinion bearing cup.
    CAUTION: A new oil baffle located between the inner drive pinion bearing cup and the axle housing bore must be installed at the time of assembly.
    Fig 10: Removing Inner Drive Pinion Bearing Cup And Oil Baffle
    G02743593Courtesy of FORD MOTOR CO.
  10. Using the special tools, remove the inner drive pinion bearing cup and oil baffle.
    11. NOTE: LH shown; RH similar.
    Fig 11: Removing Differential Case Bearings And Shims
    G02743594Courtesy of FORD MOTOR CO.
  11. Using the special tools, remove the differential case bearings and shims.
    • Tag the bearing cups and cones together to indicate which side of the carrier they were removed from.
    • Discard any damaged shims.
    12. WARNING: Gear teeth have sharp edges. Use care when handling the drive pinion. Failure to follow these instructions may result in personal injury.
    Fig 12: Removing And Discarding Bolts
    G02743595Courtesy of FORD MOTOR CO.
  12. Remove the ring gear.
    1. Remove and discard the bolts.
    2. Remove the ring gear.
  13. Remove the differential pinion shaft.
    1. Remove the differential pinion shaft lock pin.
    2. Remove the differential pinion shaft.
    Fig 13: Removing Differential Pinion Shaft Lock Pin
    G02743596Courtesy of FORD MOTOR CO.
    14. CAUTION: Make sure to note the location of the pinion gears, side gears and thrust washers to assemble in the same locations.
    Fig 14: Removing Pinion Gears, Two Side Gears And Four Thrust Washers
    G02743597Courtesy of FORD MOTOR CO.
  14. Remove the two pinion gears, two side gears and four thrust washers.
    1. Rotate the pinion gears and pinion gear thrust washers to the window and remove.
    2. Remove the side gears and side gear thrust washers.
  15. Using the special tool, remove the drive pinion bearing and drive pinion position shim.
    Fig 15: Removing Drive Pinion Bearing And Drive Pinion Position Shim
    G02743598Courtesy of FORD MOTOR CO.
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