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Item 15: Differential Case Disassembly Note

WARNING: This page is about a different car, the 2003 Mercury Mountaineer and 2003 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION: Do not damage the aluminum differential housing while carrying out these procedures.
    Fig 1: Mounting Differential Housing To Work Bench
    G01270865Courtesy of FORD MOTOR CO.
  1. Using the special tools, mount the differential housing to a work bench.
    1. Attach the special tools to the differential housing with four bolts that retain the differential housing cover to the differential housing.
    2. Attach the special tools together with two 3/8 inch x 1-1/2 inch bolts.
  2. Install the special tool by placing the spreader pins in the hole in the Housing Spreader Adapters.
    Fig 2: Placing Spreader Pins In Hole In Housing Spreader Adapters
    G01270866Courtesy of FORD MOTOR CO.
  3. Assemble the special tools.
    1. Install the special tool.
    2. Attach the special tool and position the tip in the Housing Spreader Adapter hole.
    Fig 3: Attaching Special Tools
    G01270867Courtesy of FORD MOTOR CO.
    4. CAUTION: Overspreading can damage the differential housing.
    NOTE: Tighten and loosen the Differential Carrier Spreader screw to normalize the Housing Spreader Adapters prior to taking the final Dial Indicator reading.
    Fig 4: Tightening Differential Carrier Spreader Screw
    G01270868Courtesy of FORD MOTOR CO.
  4. Spread the differential housing to the specification.
    1. Adjust the special tool to zero.
    2. Tighten the screw until the differential housing is spread to the specification.
    3. Remove the special tool.
    5. CAUTION: Mark the position and location of the differential bearing caps as the arrows may not be visible. Always install the differential bearing caps in their identical location and position.
    Fig 5: Removing Differential Bearing Caps
    G01270869Courtesy of FORD MOTOR CO.
  5. Remove the differential bearing caps.
    1. Remove the bolts.
    2. Remove the differential bearing caps.
    6. CAUTION: Use wood blocks to avoid damaging the differential housing.
    Fig 6: Removing Differential Assembly
    G01270870Courtesy of FORD MOTOR CO.
  6. Remove the differential assembly.
    1. Position wood blocks at the top and bottom of the differential case.
    2. Pry the differential assembly and the differential bearing shims out of the differential housing.
    3. Mark the bearing cups and shims for location on installation.
    • Remove the special tool.
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