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Home >> Ford >> 2002 >> Crown Victoria Base, 4.6 9 >> Repair and Diagnosis (Single Page) >> Drivelines & Axles >> Differentials & Drive Axles >> Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear >> In-Vehicle Repair >> Differential Case >> Removal

Differential Case: Removal

  1. Remove the axle shafts (4234). For additional information, refer to AXLE SHAFT .
  2. Wipe the lubricant from the internal working parts and inspect the parts for wear and damage.
  3. Rotate the differential assembly to check for roughness indicating bearing/gear damage.
    Fig 1: Rotating Differential Assembly
    G01940941Courtesy of FORD MOTOR CO.
  4. Using the special tool, measure and note the differential ring gear backface runout.
    Fig 2: Measuring Differential Ring Gear Backface Runout
    G01940942Courtesy of FORD MOTOR CO.
    5. CAUTION: Mark the position of the differential bearing caps, as the arrows may not be visible. Always install the bearing caps in their identical locations and positions.
    Fig 3: Identifying Differential Bearing Caps Bolts
    G01940943Courtesy of FORD MOTOR CO.
  5. Remove the differential bearing caps.
    1. Remove the bolts.
    2. Remove the differential bearing caps.
    6. WARNING: Do not allow the differential assembly to fall.
    CAUTION: Place a wood block between the pry bar and the differential housing (4010) to protect the machined surface from damage.
    Fig 4: Removing Differential Assembly From Differential Housing
    G01940944Courtesy of FORD MOTOR CO.
  6. Using a pry bar and a wood block, remove the differential assembly from the differential housing.
  7. Remove the bolts.
    Fig 5: Identifying Ring Gear Bolts
    G01940945Courtesy of FORD MOTOR CO.
    8. CAUTION: Do not damage the differential ring gear bolt hole threads.
    Fig 6: Identifying Differential Ring Gear & Bolt Holes
    G01940946Courtesy of FORD MOTOR CO.
  8. Insert a punch in the bolt holes, and drive off the differential ring gear.
  9. If the differential ring gear backface runout measurement, taken at the beginning of this procedure, did not exceed the specification, proceed to the appropriate procedure as necessary: DRIVE PINION , DIFFERENTIAL CASE & RING GEAR - CONVENTIONAL  or DIFFERENTIAL CASE & RING GEAR - TRACTION-LOK®  in this section, or to Installation in this procedure. If the differential ring gear backface runout measurement, taken at the beginning of this procedure, exceeded the specification, the cause may be a warped differential ring gear, differential case/differential bearing damage. Proceed as follows to verify the cause of the excessive runout.
  10. Position the differential assembly, including the differential bearing cups (4222) and differential bearing shims (4067), in the differential housing. Install the differential bearing caps and the bolts.
    Fig 7: Tightening Differential Bearing Cap Bolts
    G01940947Courtesy of FORD MOTOR CO.
  11. Position the special tool.
    1. Rotate the differential case to verify that the differential bearings (4221) have seated correctly.
    2. Position the special tool.
    Fig 8: Checking Seat Of Differential Bearings
    G01940948Courtesy of FORD MOTOR CO.
  12. Measure and note the differential case runout.
    • If the runout does not exceed the specification, install a new differential ring gear and pinion. For additional information, refer to DRIVE PINION  and to INSTALLATION  in this procedure.
    • If the runout exceeds the specification, the differential ring gear is true and the concern is due to either differential case/differential bearing damage. Proceed as follows.
    Fig 9: Checking Differential Case Runout
    G01940949Courtesy of FORD MOTOR CO.
  13. Using the special tools, remove the differential bearings.
    Fig 10: Removing Differential Bearings With 2-jaw Bearing Puller
    G01940950Courtesy of FORD MOTOR CO.
  14. Using the special tool, install the new differential bearings.
    Fig 11: Installing Differential Bearings
    G01940951Courtesy of FORD MOTOR CO.
  15. Position the differential assembly, including the differential bearing cups and differential bearing shims in the differential housing. Tighten differential bearing caps to specification.
    Fig 12: Tightening Differential Bearing Caps
    G01940952Courtesy of FORD MOTOR CO.
  16. Position the special tool.
    1. Rotate the differential case to verify that the differential bearings have seated correctly.
    2. Position the special tool.
    Fig 13: Seating Differential Bearings
    G01940953Courtesy of FORD MOTOR CO.
  17. Measure the differential case runout.
    Fig 14: Measuring Differential Case Runout
    G01940954Courtesy of FORD MOTOR CO.
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