Final Drive Carrier and Differential Assembly: Disassembly

Inspect the differential for wear or damage. Install new components as required.
1. Differential housing
2. Differential bearing shim
3. Differential housing bearing
4. Pinion shaft roll pin
5. Pinion shaft
6. Pinion thrust washer
7. Pinion gear
8. Side gear thrust washer
9. Differential side gear
  
  Fig 1: Inspecting Differential For Wear Or Damage
  Courtesy of FORD MOTOR CO.

CAUTION: Do not disassemble the planet carrier

NOTE: If the measurement exceeds specification, install a new complete final drive carrier. If the measurement is within specification, continue with the diagnostic procedure.

Fig 2: Measuring Final Drive Planet Gear End Play With Feeler Gauge

Courtesy of FORD MOTOR CO.

Measure the final drive planet gear end play with a feeler gauge.

NOTE: Do not remove the final drive pinion shaft retaining ring

Remove the differential pinion shaft.
1. Remove the pinion shaft roll pin.
2. Remove the differential pinion shaft.
  
  Fig 3: Removing Differential Pinion Shaft
  Courtesy of FORD MOTOR CO.
Remove the pinion gears and thrust washers.
- Turn the differential pinion gears 90 degrees and remove.
  
  Fig 4: Removing Pinion Gears And Thrust Washers
  Courtesy of FORD MOTOR CO.
Remove the differential side gears and differential side gear thrust washers.

Fig 5: Removing Differential Side Gears And Differential Side Gear Thrust Washers
Courtesy of FORD MOTOR CO.
Clean all parts thoroughly in clean solvent and blow dry with moisture-free regulated compressed air.
Inspect the differential parts for damage and wear.
- Gear teeth.
- Thrust washer surface.
- Thrust bearing surface.
- Pinion shaft.
Inspect the final drive planet and carrier.
1. Pinion gear teeth.
2. Thrust bearing surfaces.
3. Bushing surfaces.
  
  Fig 6: Inspecting Final Drive Planet And Carrier
  Courtesy of FORD MOTOR CO.