Q: How to service and repair the differential carrier of the Dana S110 rear drive axle on 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.
Q: How to service and repair the axle shaft of a 8.8 Inch Rear Differential on Ford F-150?
A: Start your Ford 8.8 Inch Rear Differential axle shaft maintenance by elevating the vehicle followed by tire wheel removal and subsequent drain of the lubricant into a reuse container. A clean container should receive the rear axle housing lubricant after removing 10 differential housing cover bolts to extract the differential housing cover. Drum brake vehicles require removal of the rear brake drum but disc brake vehicles need removal of the rear caliper followed by suspension of the brake caliper with wires then window the brake disc installation. Begin the procedure by giving the differential pinion shaft lock bolt the boot and pulling out the shaft. The removal process needs caution to maintain intact rubber O-rings which fit into the axle shaft grooves during U-washer and axle shaft removal. A small amount of grease should be applied to the wheel bearing oil seal lips before installing the two axle shafts while maintaining the U-washer rubber O-ring integrity in the grooves. Install U-washers onto the button ends of axle shafts before pulling the shafts in the outward direction. The differential pinion shaft requires a new lock bolt replacement unless unavailable when performing installation by using threadlock on the threads to secure the shaft to the case lock bolt hole. A rear brake drum installation should be completed on vehicles with drum brakes and a rear brake disc and caliper installation must occur on vehicles with disc brakes. Apply new continuous sealant to the differential housing cover after cleaning its mating surface. Install the cover within 15 minutes to prevent needing an additional sealant application. When installing the differential housing cover and 10 bolts users must add 2.37 liters (5 pints) of specified lubricant into the rear axle housing. Finish the process by cleaning wheel mounting surfaces until they show proper metal contact before putting on the tire-wheel installation.
Q: How to service and repair the 7.5-inch rear differential on Ford Ranger?
A: Begin repairs and servicing of the Ford 7.5-inch rear differential by first lifting the vehicle and securing it. Then remove the wheel along with the tire from the assembly. You need to place lubricant drainage into clean storage and then separate the differential housing cover (4033) through its 10 bolts which need removal. The lubricant draining process of the 4010 rear axle housing must be completed before proceeding to remove both differential housing cover and rear brake drums. Under the following step remove the differential pinion shaft while using the lock bolt removal method to pull out the shaft. It is crucial to maintain caution during U-washer removal because damaging the rubber O-rings inside axle shaft grooves can occur when pushing the axle shafts inside. Extract the wheel bearing oil seal without damaging it while removing the two axle shafts. Wash the machined areas on the rear axle housing and differential housing cover while keeping the inside of the rear axle (4001) shielded from contaminants during the procedure. The axle shafts should get installed while using grease to lubricate the lip of the wheel bearing oil seal and avoiding damage to the rubber O-rings. Position the U-washers at the end of axle shaft buttons then extend the shafts outward. Threadlock and sealer should be applied to new pinion shaft lock bolt threads when no alternative bolt is available to secure the differential pinion shaft by aligning it with the case lock bolt hole. The differential housing cover needs a new continuous bead of specified thickness sealant which must be installed within 15 minutes after application to prevent needing new sealant. Filling the rear axle housing with 2.4 liters (5 pints) of lubricant should be done after installing the differential housing cover which must be secured with all ten bolts. Reinstall the wheels and tires and lower the vehicle.