LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2005 >> Expedition 4WD >> Repair and Diagnosis >> External Pages >> Different car >> Section 470 (Front Drive Axle/Differential) >> Disassembly And Assembly >> Axle >> Disassembly

Disassembly And Assembly: Axle: Disassembly

WARNING: This page is about a different car, the 2006 Lincoln Navigator and 2006 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 .
  2. Remove the differential housing cover.
    • Drain the fluid.
    • Remove the bolts.
    • Remove the differential housing cover.
      Fig 1: Identifying Differential Housing Cover & Bolts
      G04626379Courtesy of FORD MOTOR CO.
    3. CAUTION: The fixture mounting bolts must have the minimum specified thread engagement in the carrier.
    Fig 2: Identifying Special Tool (307-003)
    G04626380Courtesy of FORD MOTOR CO.
  3. Install the special tool.
  4. Using a suitable axle shaft remover, remove the right hand and left hand axle shafts.
    Fig 3: Identifying Axle Shaft Remover
    G04626381Courtesy of FORD MOTOR CO.
  5. Remove the axle housing tube.
    Fig 4: Removing Axle Housing Tube
    G04626382Courtesy of FORD MOTOR CO.
    6. CAUTION: The housing spreader adapter bolts must have the minimum specified thread engagement in the carrier.
    Fig 5: Identifying Special Tools (205-368, 205-335)
    G04626383Courtesy of FORD MOTOR CO.
  6. Install the special tools.
  7. Position the special tool on the spreader adapters.
    Fig 6: Positioning Special Tool (205-001) On Spreader Adapters
    G04626384Courtesy of FORD MOTOR CO.
  8. Install the special tools.
    • Position the adapter tip in the spreader adapter hole.
      Fig 7: Positioning Adapter Tip In Spreader Adapter Hole After Installing Special Tools (100-D004, 1005-D005, 308-021)
      G04626385Courtesy of FORD MOTOR CO.
    9. CAUTION: Overspreading can damage the axle housing.
  9. 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
      G04626386Courtesy of FORD MOTOR CO.
    10. 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.
  10. Mark and remove the differential bearing caps.
    1. Remove the bolts.
    2. Remove the differential bearing caps.
      Fig 9: Identifying Differential Bearing Caps & Bolts
      G04626387Courtesy of FORD MOTOR CO.
    11. CAUTION: Use wood blocks to avoid axle housing damage.
  11. Remove the differential assembly from the axle housing.
    1. Position the wood blocks.
    2. Position and push down on the 2 pry bars.
    3. Remove the differential assembly.
    4. Remove the special tool.
      Fig 10: Removing Differential Assembly From Axle Housing
      G03912955Courtesy of FORD MOTOR CO.
  12. Index-mark the axle universal joint flange to the pinion stem.
    Fig 11: Identifying Index-Mark On Pinion Flange And Drive Pinion Gear
    G03928220Courtesy of FORD MOTOR CO.
  13. Install the special tool and loosen, but do not remove, the pinion nut.
    Fig 12: Holding Pinion Flange Using Special Tool (205-126)
    G03928261Courtesy of FORD MOTOR CO.
  14. 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 Using Special Tool (205-D072)
    G04626391Courtesy of FORD MOTOR CO.
  15. Remove the nut and the flange.
  16. Using the special tool and a soft hammer, remove the pinion gear.
    Fig 14: Removing Pinion Gear Using Special Tool (205-460)
    G04626392Courtesy of FORD MOTOR CO.
  17. Discard the drive pinion collapsible spacer.
    Fig 15: Locating Drive Pinion Collapsible Spacer
    G03928265Courtesy of FORD MOTOR CO.
    18. CAUTION: Do not damage the carrier housing while removing the pinion seal.
  18. 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 Drive Pinion Oil Seal
      G03878521Courtesy of FORD MOTOR CO.
  19. Remove the outer pinion bearing.
  20. Using the special tools, remove the inner pinion bearing cup.
    Fig 17: Removing Inner Pinion Bearing Cup Using Special Tools (100-001, 308-047)
    G04626395Courtesy of FORD MOTOR CO.
    21. NOTE: The pinion bearing oil baffle aids in bearing lubrication. Normally, it is not necessary to remove the baffle.
    Fig 18: Locating Pinion Bearing Oil Baffle
    G04626396Courtesy of FORD MOTOR CO.
  21. If necessary, remove the pinion bearing oil baffle.
  22. Remove the outer pinion bearing cup by tapping alternately on each side to prevent the cup from cocking.
    Fig 19: Locating Outer Pinion Bearing Cup
    G04626397Courtesy of FORD MOTOR CO.
  23. Using the special tool and a suitable press, remove the pinion bearing.
    Fig 20: Removing Pinion Bearing Using Press and Special Tool (205-055)
    G04626398Courtesy of FORD MOTOR CO.
    24. 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: Locating Drive Pinion Bearing Adjustment Shim
    G04626399Courtesy of FORD MOTOR CO.
  24. Remove and measure the drive pinion bearing adjustment shim.
  25. Remove the 10 bolts and the ring gear.
    • Use a drift punch to separate the ring gear from the differential case.
      Fig 22: Locating Differential Ring Gear Bolts
      G03912881Courtesy of FORD MOTOR CO.
  26. Using the special tools, remove the differential bearings.
    Fig 23: Removing Differential Bearings Using Special Tools (205-D061, 205-D072)
    G04626401Courtesy of FORD MOTOR CO.
scientia non olet · About LEMON Manuals