Differential Carrier: Service and Repair

Removal

WARNING: Do not use heat when disassembling a drive axle. To do so will destroy heat treat properties and weaken or distort axle components. Failure to follow these instructions may result in personal injury.

1. CAUTION: Steam clean the axle prior to removal from the vehicle. Dirt is abrasive and will cause premature wear of otherwise usable parts.

Steam clean the axle assembly.





2. Set the parking brake.





3. Chock the wheels.





4. Drain the axle lubricant into a suitable container.
1. Remove the drain plug.
2. Clean and install the drain plug when the lubricant has drained.





5. Disconnect the rear anti-lock brake sensor electrical connector.





6. Index-mark and disconnect the driveshaft, and position it aside.





7. Loosen the pinion hex nut if drive pinion disassembly is necessary.

8. WARNING: Do not strike the axle shaft flange directly with a steel hammer or sledge. This will crack and splinter the flange. Failure to follow these instructions may result in personal injury.

CAUTION: Do not pry or chisel the axle shaft flange away from the hub. This will damage the sealing surface.

Note: Mark the left or right axle shaft flange for proper orientation during installation.





Remove the axle shafts.





9. Remove all but the two top carrier-to-axle housing retaining bolts, noting the length and position of each bolt.

10. WARNING: Secure the carrier to the jack to prevent it from falling when removing it from the axle housing. Failure to follow these instructions may result in personal injury.





Remove the carrier from the axle housing.
1. Position a suitable jack under the carrier.
2. Remove the remaining retaining bolts.
3. Use the slots to separate the carrier approximately 25.4 - 50.8 mm (1 - 2 inches) from the axle housing.
4. Secure the carrier to a suitable jack, and remove, the carrier from the axle housing.

11. CAUTION:
^ Alkaline cleaning solutions will damage machine surfaces. Use only emulsion cleaners or petroleum based cleaning solvent.
^ Use only soft, clean, lintless towels to dry the components.
^ After drying, lightly coat the parts with rust inhibitor or clean lubricant to prevent damage from corrosion. Wrap all parts that are going to be in storage for a prolonged period in wax paper.

Clean and dry the components as necessary.

12. Note: The gear set shown removed for clarity.





Inspect the gear set for pitting, scoring, wear and damage.





13. Inspect the splines for wear, cracking and distortion from twisting.





14. Inspect the axle flange O-ring.





15. Clean the axle housing interior, the axle and carrier housing sealing surfaces, and the carrier mounting bolt hole threads. Inspect the housing for stripped and damaged threads and bending fatigue.
16. If carrier disassembly is necessary, refer to Differential Case and Ring Gear.

Installation

1. CAUTION: The gasket material must cure for one hour before filling the axle with lubricant.





Apply a continuous bead of Ford Gasket Maker FSAZ-19B508-AB or equivalent meeting Ford specification WSK-M2G348-A5 onto the axle housing mounting flange and around each bolt hole.





2. Thread two studs into the axle housing 180 degrees apart. This will eliminate rotation of the carrier assembly after it makes contact with the gasket material.

3. WARNING: Secure the carrier to the jack to prevent it from failing. Failure to follow these instructions may result in personal injury.





Position the carrier into the axle housing.

4. CAUTION: Make sure the bolt threads are clean.





Apply Threadlock 262E2FZ-19554-B or equivalent meeting Ford specification WSK-M2G351-A6 to the bolt threads, and install the bolts.
^ Remove the two alignment studs only after installing several of the bolts.
^ Tighten the bolts in a cross pattern.





5. Install the axle shafts.





6. Connect the driveshaft.





7. Connect the rear anti-lock brake sensor electrical connector.





8. Remove the fill plug.

9. CAUTION: A lubricant level close enough to the bottom of the fill hole to be seen or touched is not sufficient. The lubricant must be level with the fill hole.





Fill the axle with Motorcraft SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-01, or equivalent meeting Ford specification WSP-M2Cl97-A until the lubricant is level with the fill hole.





10. Clean and install the fill plug.





11. Remove the wheel chocks.





12. Release the parking brake.