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Home >> Ford >> 2002 >> Expedition 5.4 L, RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 249 (Front Drive Axle/Differential) >> Disassembly And Assembly >> Axle - Front Drive >> Disassembly
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Axle - Front Drive: Disassembly

WARNING: This page is about a different car, the 2003 Lincoln Navigator and 2003 Ford Expedition. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the front drive axle assembly. For additional information, refer to AXLE ASSEMBLY - FRONT DRIVE .
  2. Remove the differential housing cover.
    1. Remove the drain plug.
    2. Drain the fluid.
    3. Remove the bolts.
    4. Remove the differential housing cover.
      Fig 1: Removing Differential Housing Cover
      G01560995Courtesy of FORD MOTOR CO.
    3. CAUTION: The fixture mounting bolts must have the minimum specified thread engagement in the carrier.
    Fig 2: Installing Special Tool
    G01560996Courtesy of FORD MOTOR CO.
  3. Install the special tool.
  4. Remove the right hand axle shaft.
    1. Remove the snap ring.
    2. Remove the axle shaft.
  5. Remove the axle housing tube.
    Fig 3: Removing Axle Housing Tube
    G01560997Courtesy of FORD MOTOR CO.
  6. Remove the axle shaft.
    1. Remove the snap ring.
    2. Remove the axle shaft.
      Fig 4: Removing Axle Shaft
      G01560998Courtesy of FORD MOTOR CO.
    7. CAUTION: The housing spreader adapter bolts must have the minimum specified thread engagement in the carrier.
    Fig 5: Installing Special Tools
    G01560999Courtesy of FORD MOTOR CO.
  7. Install the special tools.
  8. Position the special tool on the spreader adapters.
    Fig 6: Positioning Special Tool On Spreader Adapters
    G01561000Courtesy of FORD MOTOR CO.
  9. Install the special tools.
    • Position the adapter tip in the spreader adapter hole.
      Fig 7: Installing Special Tools
      G01561001Courtesy of FORD MOTOR CO.
    10. CAUTION: Overspreading can damage the axle housing.
  10. Spread the axle housing to the specification.
    1. Adjust the special tool to zero.
    2. Tighten the housing spreader screw to spread the axle housing to the specification.
    3. Remove the special tool.
      Fig 8: Spreading Axle Housing To Specification
      G01561002Courtesy of FORD MOTOR CO.
    11. CAUTION: Mark the differential bearing caps Top or Bottom and LH or RH appropriately before removing them. Always install the bearing caps in their original place and position.
  11. Mark and remove the differential bearing caps.
    1. Remove the bolts.
    2. Remove the differential bearing caps.
      Fig 9: Removing Differential Bearing Caps
      G01561003Courtesy of FORD MOTOR CO.
    12. CAUTION: Use wood blocks to avoid axle housing damage.
  12. Remove the differential assembly from the axle housing.
    1. Position the wood blocks.
    2. Position and push down on the two pry bars.
    3. Remove the differential assembly.
    4. Remove the special tool.
      Fig 10: Removing Differential Assembly From Axle Housing
      G01561004Courtesy of FORD MOTOR CO.
  13. Index-mark the axle universal joint flange to the pinion stem.
    Fig 11: Identifying Index-Mark On Axle Universal Joint Flange And Pinion Stem
    G01561005Courtesy of FORD MOTOR CO.
  14. Install the special tool and loosen, but do not remove, the pinion nut.
    Fig 12: Installing Special Tool And Loosen
    G01561006Courtesy of FORD MOTOR CO.
  15. With the pinion nut still engaged by a few threads, use the special tool to separate the axle universal joint flange from the pinion gear.
    Fig 13: Separating Axle Universal Joint Flange From Pinion Gear
    G01561007Courtesy of FORD MOTOR CO.
  16. Remove the nut and the flange.
  17. Using the special tool and a soft hammer, remove the pinion gear.
    Fig 14: Removing Pinion Gear
    G01561008Courtesy of FORD MOTOR CO.
  18. Discard the drive pinion collapsible spacer.
    Fig 15: Discarding Drive Pinion Collapsible Spacer
    G01561009Courtesy of FORD MOTOR CO.
    19. CAUTION: Do not damage the carrier housing while removing the pinion seal.
  19. Remove the pinion seal and slinger.
    • Pry up on the seal flange. Install gripping pliers, and strike with a hammer to remove the seal.
      Fig 16: Removing Pinion Seal And Slinger
      G01561010Courtesy of FORD MOTOR CO.
  20. Remove the outer pinion bearing.
  21. Using the special tools, remove the inner pinion bearing cup.
    Fig 17: Removing Inner Pinion Bearing Cup
    G01561011Courtesy of FORD MOTOR CO.
    22. NOTE: The pinion bearing oil baffle aids in bearing lubrication. Normally, it is not necessary to remove the baffle.
    Fig 18: Removing Pinion Bearing Oil Baffle
    G01561012Courtesy of FORD MOTOR CO.
  22. If necessary, remove the pinion bearing oil baffle.
  23. Remove the outer pinion bearing cup by tapping alternately on each side to prevent the cup from cocking.
    Fig 19: Removing Outer Pinion Bearing Cup By Tapping Alternately On Each Side To Prevent Cup From Cocking
    G01561013Courtesy of FORD MOTOR CO.
  24. Using the special tool and a suitable press, remove the pinion bearing.
    Fig 20: Removing Pinion Bearing
    G01561014Courtesy of FORD MOTOR CO.
    25. NOTE: A drive pinion bearing adjustment shim sits under the pinion bearing. Use a micrometer to measure the shim thickness. Record the measurement for comparison to the shim gauge reading taken prior to installing the pinion bearing.
    Fig 21: Removing And Measuring Drive Pinion Bearing Adjustment Shim
    G01561015Courtesy of FORD MOTOR CO.
  25. Remove and measure the drive pinion bearing adjustment shim.
  26. Remove the ten bolts and the ring gear.
    • Use a drift punch to separate the ring gear from the differential case.
      Fig 22: Removing Bolts And Ring Gear
      G01561016Courtesy of FORD MOTOR CO.
  27. Using the special tools, remove the differential bearings.
    Fig 23: Removing Differential Bearings
    G01561017Courtesy of FORD MOTOR CO.
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