Disassembly And Assembly Of Subassemblies: Differential: Disassembly

WARNING: This page is about a different car, the 2006 Mercury Milan and 2006 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

Inspect the differential for wear or damage.
- Inspect for damaged or worn gears.
- Inspect for worn or damaged differential bearings.
- Install new components as necessary.
Remove the differential side gears and thrust washers.
- Rotate the differential side gears to remove.
  
  Fig 1: Locating Differential Side Gears
  Courtesy of FORD MOTOR CO.
Using the special tools, remove the differential bearing.
- Always install new bearings and cups as a set. Do not install one without the other.
  
  Fig 2: Locating Special Tools And Differential Bearing
  Courtesy of FORD MOTOR CO.
Remove the speedometer drive gear.

Fig 3: Locating Special Tools And Speedometer Drive Gear
Courtesy of FORD MOTOR CO.
Rotate the differential assembly with the speedometer drive gear side facing downward. Remove the other differential bearing.
- Always install new bearings and cups as a set. Do not install one without the other.
  
  Fig 4: Locating Special Tools And Differential Bearing
  Courtesy of FORD MOTOR CO.
Remove and discard the differential pinion shaft lock pin.

Fig 5: Locating Differential Pinion Shaft Lock Pin
Courtesy of FORD MOTOR CO.
Remove the differential pinion shaft, the differential pinon gears and the thrust washers.