7.5 Inch Ring Gear
SENSOR, ANTI-LOCK BRAKE1. Clean axle mounting surface, using caution to prevent dirt from entering axle housing.
2. Remove hold-down bolt. Remove rear brake anti-lock sensor.
DIFFERENTIAL CASE REMOVAL
1. All service operations on the differential case and the drive pinion can be performed with the axle housing installed in the vehicle.
Raise the vehicle on drive-thru hoist and place jackstands under the rear frame crossmember. Lower the hoist so that the rear axle assembly drops down far enough for working ease.
2. Remove the axle housing cover from the carrier rear face and drain the lubricant. Inspect the differential case and drive pinion before removal.
NOTE: The next step requires removal of the axle housing cover. On Aerostar, once removed, the plastic axle housing cover must be replaced with a new one.
3. Check and record the ring gear runout.
^ Check and record the ring gear backlash.
4. Remove the rear wheels and brake drums.
5. Remove the axle shafts.
6. Make scribe marks on the driveshaft end yoke and the rear axle companion flange to ensure proper alignment at assembly. If required, remove the damper assembly from the carrier. Disconnect the driveshaft end yoke from the rear axle companion flange. Remove the driveshaft assembly from the vehicle.
7. Mark differential bearing caps to make sure they are installed in original positions during assembly.
8. Loosen the differential bearing cap bolts.
^ Bearing caps must be installed in their original positions and locations. Triangles embossed on bearing caps must face outboard toward the axle shafts.
9. Pry the differential case, differential bearing cups and differential bearing shims out until they are loose in the bearing caps. Remove the bearing caps and remove the differential case from the carrier. If the ring gear is removed from the differential case, coat ring gear bolts with Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 prior to installation. Tighten to 95-115 Nm (70-85 ft. lbs.).
^ If a high ratio ring gear (3.73:1-4.10:1) is removed, make sure the drive pinion shaft is installed in the differential case before installing the ring gear on the differential case.
NOTE: Before removing differential case from carrier, inspect it and determine if differential case runout check is necessary.
DRIVE PINION REMOVAL
1. Mark the rear axle companion flange in relation to the drive pinion stem. Hold the rear axle companion flange with the proper tool and remove the pinion nut. If a new rear gear and pinion is being installed, the driveshaft centering socket yoke need not be marked.
2. Remove the rear axle companion flange with Differential Side Bearing Puller T77F-4220-B1. With a soft-faced hammer, drive the pinion out of the bearing cone and roller and remove it through the rear of the carrier casting.
NOTE: Before removing rear axle companion flange, inspect it and determine if companion flange runout check is necessary.
3. Remove the pinion seal with Seal Remover TOOL-1175-AC or equivalent and Impact Slide Hammer T50T-100-A. Remove the bearing cone and roller and oil slinger from the carrier casting.
4. Remove the drive pinion, front bearing cone spacer and pinion seal.
5. To remove the rear drive pinion bearing cone, use Pinion Bearing Cone Remover T71P-4621-B as shown. Measure the shim found under the differential pinion bearing with a micrometer. Record the thickness.
6. Before installing the drive pinion bearing cone on the drive pinion, a drive pinion shim must be selected.
PINION BEARING CUP REMOVAL
1. If the pinion bearing cups are to be replaced, tap alternately (with a brass drift of suitable length) on each side of the pinion bearing cups during removal to prevent them from becoming cocked in the differential carrier bore.
NOTE: Do not remove the pinion bearing cups from the differential carrier unless damaged or unless new bearings are to be installed.