Differential Case

Differential Case

Disassembly
1. Remove the differential assembly from the differential carrier housing.





2. Remove the ring gear.
^ Remove the ten bolts.
^ Use a drift punch to separate the ring gear from the differential case.





3. Remove the differential pinion shaft bolt.





4. Remove the differential pinion shaft.





5. Remove the differential pinion thrust washers and the differential pinion gears.
1 Rotate the differential pinion gears to the differential case window, and remove them.
2 Separate the thrust washers from the gears.





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

Assembly
1. Lubricate the differential side gear thrust washers and the differential side gear journals with Motorcraft SAE 75W-90 Premium 4x4 Front Axle Lubricant XY-75W90-TQL, or equivalent meeting Ford specification WSP-M2C201-A.





2. Position the differential side gear thrust washers on the differential side gears.





3. Position the differential side gears.





4. Lubricate the differential pinion thrust washers and the differential pinion gears and assemble them.
^ Use Motorcraft SAE 75W-90 Premium 4x4 Front Axle Lubricant XY-75W90-TQL or equivalent meeting Ford specification WSP-M2C201-A.





5. Engage the differential pinion gears opposite the differential side gear.





6. Rotate the differential pinion gears to align with the differential pinion shaft bore.





7. Insert the differential pinion shaft.





8. NOTE: If a new pinion shaft bolt is unavailable, coat the threads with Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5 prior to installation.

Install a new differential pinion shaft bolt.





9. CAUTION: Do not press on the bearing.

Install the ring gear.
1 Position three bolts to align the holes in the ring gear and the differential case.
2 Using a suitable press, install the ring gear.





10. Install the remaining bolts.