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Axle Assembly: Disassembly

WARNING: This page is about a different car, the 2005 Lincoln LS. However, it is still accessible from the selected car via links, so may be relevant.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. Remove the rear axle assembly. For additional information, refer to AXLE ASSEMBLY  in this article .
  3. Drain the axle.
    Fig 1: Exploded View Of Rear Axle Assembly
    G03995367Courtesy of FORD MOTOR CO.
    4. CAUTION: The machined surfaces on the differential housing and the differential housing cover must be clean and free of oil before applying the new Silicone Gasket and Sealant. Cover the inside of the axle before cleaning the machined surface to prevent contamination.
  4. Remove the differential housing cover.
  5. Mount the differential assembly in the special tool.
    Fig 2: Identifying Differential Assembly & Special Tool
    G03995368Courtesy of FORD MOTOR CO.
  6. Install a Nm (lb-in) torque wrench on the differential drive pinion nut and record the torque necessary to maintain rotation of the differential pinion gear through several revolutions.
    Fig 3: Checking Differential Pinion Bearing Preload
    G03995201Courtesy of FORD MOTOR CO.
  7. Index-mark the rear axle pinion flange to the differential pinion stem.
    Fig 4: Marking Index-Mark On Rear Axle Pinion Flange To Differential Pinion Stem
    G03995203Courtesy of FORD MOTOR CO.
    8. CAUTION: After removing the differential drive pinion nut, discard it. Use a new differential drive pinion nut for installation.
    Fig 5: Removing Differential Drive Pinion Nut
    G03995202Courtesy of FORD MOTOR CO.
  8. Use the special tool to hold the rear axle pinion flange while removing the differential drive pinion nut.
  9. Using the special tool, remove the rear axle pinion flange.
    Fig 6: Removing Rear Axle Pinion Flange
    G03995236Courtesy of FORD MOTOR CO.
  10. Use a screwdriver to force up the metal flange of the rear pinion oil seal. Install gripping pliers and strike with a hammer to remove the rear pinion oil seal.
    Fig 7: Removing Drive Pinion Seal
    G03878521Courtesy of FORD MOTOR CO.
  11. Remove the rear pinion oil seal slinger, outer pinion bearing and the drive pinion collapsible spacer.
  12. Force up the metal flange on the half shaft housing seal.
    Fig 8: Forcing Up Metal Flange On Half Shaft Housing Seal
    G03995238Courtesy of FORD MOTOR CO.
  13. Install gripping pliers and strike with a hammer to remove the halfshaft housing seal from the housing.
    Fig 9: Removing Halfshaft Housing Seal From Housing
    G03995239Courtesy of FORD MOTOR CO.
  14. Repeat for the other side.
  15. Remove the differential bearing cap bolts and bearing cap after index-marking the original location.
    Fig 10: Marking Index Mark On Differential Bearing Cap
    G03995240Courtesy of FORD MOTOR CO.
  16. Remove the selective snap ring, differential bearing shim and the differential bearing cups.
  17. Remove the differential case assembly.
  18. Remove the differential ring gear bolts, then the differential ring gear.
  19. Using the special tools, remove the differential bearing.
    • Repeat for the other side.
    Fig 11: Removing Differential Bearing
    G03995377Courtesy of FORD MOTOR CO.
    20. NOTE: Drive the differential pinion shaft roll pin from the differential pinion shaft after the differential pinion shaft is removed from the differential case. Discard the differential pinion shaft roll pin.
    Fig 12: Exploded View Of Differential Case
    G03995378Courtesy of FORD MOTOR CO.
  20. If necessary, disassemble the differential case as follows:
    1. Using a drift punch and a hammer, drive the differential pinion shaft roll pin into the differential pinion shaft until bottomed out. The differential pinion shaft roll pin will remain in the differential pinion shaft when the differential pinion shaft is removed from the differential case.
    2. Remove the differential pinion shaft.
    3. Remove the differential pinion gears and differential pinion gear thrust washers.
    4. Remove the differential side gears and differential side gear thrust washers.
  21. Remove the differential pinion gear.
  22. Using the special tool and a suitable press, remove the inner pinion bearing.
    1. Position the special tool under the inner pinion bearing.
    2. Press the inner pinion bearing off of the differential pinion gear.
    Fig 13: Removing Differential Pinion Gear
    G03995379Courtesy of FORD MOTOR CO.
  23. Using a drift punch and a hammer, remove the inner pinion bearing cup.
  24. Using a drift punch and a hammer, remove the outer pinion bearing cup.
    Fig 14: Removing Outer Pinion Bearing Cup
    G03995243Courtesy of FORD MOTOR CO.
  25. If necessary, remove the rear axle housing support insulator. For additional information, refer to REAR AXLE HOUSING SUPPORT INSULATOR  in this article .
  26. Inspect all components for wear or damage. Install new components as necessary.
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