Differential Case: Disassembly

WARNING: This page is about a different car, the 2013 Ford F-550 Super Duty, 2013 Ford F-450 Super Duty, 2013 Ford F-350 Super Duty, and 2013 Ford F-250 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.

Remove the differential carrier. For additional information, refer to DIFFERENTIAL CARRIER - DANA 60 .
Using the Drive Pinion/Differential Carrier Puller, remove the differential bearings.

Fig 1: Removing Differential Bearings Using Drive Pinion/Differential Carrier Puller
Courtesy of FORD MOTOR CO.
Remove the differential bearing shims.

Fig 2: Locating Differential Bearing Shims
Courtesy of FORD MOTOR CO.
NOTE: Place shop towels under the ring gear to prevent ring gear damage.

NOTE: Discard the bolts after removing them from the differential case.

Remove the ring gear.
- Remove and discard 8 of the 12 ring gear bolts. Leave 4 loosely assembled bolts spaced equally apart from each other.
- Tap each of the 4 bolt heads alternately with a soft-faced hammer to loosen the ring gear. Remove the bolts and the ring gear. Discard the bolts.
  
  Fig 3: Removing Ring Gear Bolts
  Courtesy of FORD MOTOR CO.
Using a hammer and a small drift, drive out the differential pinion shaft lockpin.

Fig 4: Removing Differential Pinion Shaft Lock Pin
Courtesy of FORD MOTOR CO.
Using a suitable tool, remove the differential pinion shaft.

Fig 5: Removing Differential Pinion Shaft
Courtesy of FORD MOTOR CO.
Remove the differential pinion gears, pinion gear thrust washers, differential side gears and differential side gear thrust washers.

Fig 6: Locating Differential Side Gears
Courtesy of FORD MOTOR CO.
NOTE: If upon inspection, any component has score marks/chips, thoroughly clean the differential housing.

Carry out the following inspection.
- Thoroughly clean all parts.
- Inspect all parts for damage or discoloration from overheating.
  - Discard the complete differential if excessive wear is visible on all parts.
  - Discard both differential pinion gears and both differential side gears if any one of these gears are worn/damaged.
- Verify that the differential bearing bores are smooth. Remove any nicks/burrs from the mounting surfaces of the differential housing.