OEM 2003 Ford Excursion Differential

2003 Ford Excursion Differential Parts Q&A

• Q: How to service and repair the differential carrier of the Dana S110 rear drive axle on 2003 Ford Excursion?

  A: Service and repair operations for the differential carrier of the Dana S110 rear drive axle should start with steam cleaning the axle assembly to minimize abrasive dirt damage. Begin his work by engaging the parking brake, wheel chocking and draining axle lubricant through a proper container. After unfastening the bottom two bolts you can extract the liquids from the assembly. First disconnect the rear anti-lock brake sensor electrical connector and position the driveshaft aside after indexing. Drive pinion components require an adjustment of the pinion hex nut before proceeding with pinion disassembly. Mending the hub should be done without tapping the axle shaft flange with steel hammer since damages can result from this process. Keep the two top carrier-to-axle housing retaining bolts in place but remove all other retaining bolts along with both axle shafts. Note down the lengths and positions of the bolts before discarding the differential carrier housing bolts. Secure the carrier to a jack to prevent its fall but remove it from the axle housing by discarding two retaining bolts until the carrier separates 25.4 - 50.8 mm (1 - 2 inches) from the housing. Components require emulsion cleaning or petroleum-based solvents followed by a light application of rust inhibitor or clean lubricant which should be covered by wax paper for storing parts that will be kept for a prolonged period. Radial and longitudinal promoters, smoothing, deterioration rate, and damage assessment should take place for the gear set while splines need examination for wear patterns and cracking and distortion conditions. Examine the axle flange O-ring along with cleaning the interior of the axle housing and both sealing surfaces and threads of the carrier mounting bolts to determine if any threads have been stripped or bending fatigue exists. Check appropriate procedures when disassembling the carrier. Place a continuous amount of Ford Gasket Maker on the axle housing mounting flange and bolt holes before installing two studs that stop the carrier assembly from rotating. Place the carrier onto the jack while attaching it securely before guiding it into the housing with the help of the supplied studs for alignment purposes. The first step for new differential carrier housing bolt installation includes cleaning bolt threads while removing the alignment studs only when multiple bolts are in position and performing a cross-pattern bolt tightening sequence. The next step involves reinstating both axle shafts and driveshaft and anti-lock brake sensor electrical connector when present. First remove the fill plug before you add lubricant to the axle until its level height reaches the fill hole. Finish by cleaning the filter plug and reinstalling it. End the procedure by taking off wheel chocks then releasing the parking brake.