OEM 2004 Ford Excursion Differential

2004 Ford Excursion Differential Parts Questions & Experts Answers

• Q: How to service and repair the Dana S110 differential carrier on 2004 Ford Excursion?

  A: You should start carrier service and repair work on Dana S110 differentials by cleaning the axle with steam to minimize dirt impact on early part wear. After activating the parking brake and wheel chocking service you should drain the axle lubricant into an appropriate vessel. Empty the assembly through the carrier bolt and disable the rear anti-lock brake sensor connector when it exists on the vehicle. When necessary disassembly you must first index-mark and disconnect the driveshaft set aside before loosening the pinion hex nut. Striking the axle shaft flange directly with a steel hammer can cause cracking which should be avoided and the same precaution applies to preventing damage to the sealing surface by using prying or chiseling tools. Unscrew all axle shafts and keep two top differential carrier-to-axle housing retaining bolts in place while recording their positions and lengths. Then discard the entire set of differential carrier housing bolts. Place the jack underneath the carrier to prevent dropping before you completely remove the remaining retaining bolts which will produce 25.4 - 50.8 mm (1 - 2 inches) of gap between the carrier and axle housing. The components require cleaning with emulsion cleaners or petroleum-based solvents and should be dried before applying a light coating of rust inhibitor or clean lubricant to prevent corrosion. Review gear set quality by inspecting it for pitting symptoms, scoring damage, wear, and mechanical harm in addition to checking splines for wear and cracking alongside distortion issues. Examine both the O-ring of the axle flange and clean the interior of the axle housing alongside all the sealing surfaces and threads of the carrier mounting bolt holes while checking for stripped threads and bending fatigue. You need to obtain instructions from the differential case and ring gear for disassembly procedures. Install Ford Gasket Maker as a continuous bead on the axle housing mounting flange and bolt holes before installing two mounting studs into the axle housing to avoid carrier assembly rotation. After positioning the carrier into the housing through its studs the jack should securely fasten it in place. New differential carrier housing bolts should have their threads cleaned before installation but the alignment studs should come off after multiple bolts get installed and should be tightened in a cross pattern. Attach the axle shafts followed by reconnecting the driveshaft before installing the electrical connector of the rear anti-lock brake sensor when such components are present. To fill the axle with lubricant one should remove the fill plug and stop adding fluid when it reaches the same level as the fill hole and reinstall the plug. The process should end with wheel chocks removal and releasing of the parking brake.