Differential Case

Differential Case

Special Tools:

Special Tool(s)
Disassembly





1. Remove the differential ring gear.
1. Remove and discard the bolts.
2. Using a drift that will bottom out in the bolt holes, separate the differential ring gear from the differential case.





2. Drive out the differential pinion shaft roll pin.





3. Remove the differential pinion shaft.





4. CAUTION: The upper differential side gear may fall out of the case bore after removing the differential pinion gears.

Rotate the differential pinion gears to the differential case window and remove them and the differential pinion thrust washers.





5. Remove the differential side gears and the differential side gear thrust washers.





6. Assemble the special tool.





7. Position the special tool on the differential bearing.





8. Using the special tool, remove the differential bearing.
^ Repeat the procedure for the other bearing.

Assembly





1. Lubricate the differential side gear thrust washers and the differential side gears, and assemble them.
^ Use Motorcraft SAE 80W90 Thermally Stable 4x4 Axle Lubricant meeting Ford specification WSP-M2C197-A.





2. Position the differential side gear and thrust washer assemblies in the differential case.





3. Lubricate the differential pinion thrust washers and the differential pinion gears, and assemble them.
^ Use Motorcraft SAE 80W90 Thermally Stable 4x4 Axle Lubricant meeting Ford specification WSP-M2C197-A.





4. Engage the differential pinion gears between the differential side gears.





5. Rotate the differential pinion gears and align them with the differential pinion shaft bore.





6. Insert the differential pinion shaft.





7. Install the differential pinion shaft roll pin.
8. Install the differential bearing shims, the differential bearings, and the differential ring gear.