SYS.OK|MANUAL.DB● LIVE
HOMESERVICE MANUALSFORD1997CROWN VICTORIA BASE, 4.6 WREPAIR AND DIAGNOSIS (SINGLE PAGE)DRIVELINES & AXLESDIFFERENTIALS & DRIVE AXLESDIFFERENTIALS & AXLE SHAFTSOVERHAULREAR AXLE ASSEMBLYDISASSEMBLY
1997 Ford Crown Victoria Base, 4.6 W

Rear Axle Assembly: Disassembly

1997 Ford Crown Victoria Base, 4.6 WSECTION Disassembly
  1. Raise and support vehicle under rear frame crossmember. Lower hoist until axle drops down to within working range. Remove differential housing cover, and drain lubricant.
  2. Mount a Dial Indicator (4201-C) on axle housing, and measure ring gear backlash and runout. See Figure . Record readings for reassembly purposes. Ensure ring gear runout and backlash variation between teeth are within specification. See AXLE ASSEMBLY SPECIFICATIONS  . Replace ring gear and pinion if backlash variation is excessive.
  3. Remove axle shafts. See AXLE SHAFTS & BEARINGS  under REMOVAL & INSTALLATION. Remove drive shaft. See DRIVE SHAFT  under REMOVAL & INSTALLATION.
    4. NOTE: Bearing cups, caps and shims must be installed in original positions.
  4. Mark one bearing cap for reassembly reference. Note arrow position on bearing cap for reassembly reference. Loosen bearing cap bolts and bearing caps. Pry out differential case, bearing cups, and shims until they are loose in bearing caps. Remove bearing caps and differential. Mark component location for reassembly reference.
  5. Remove pinion nut and companion flange. See PINION COMPANION FLANGE & OIL SEAL  under REMOVAL & INSTALLATION. Drive pinion from front bearing using soft-face hammer. Remove pinion from rear of axle housing. Pry oil seal from axle housing.
  6. Remove front bearing. Remove pinion bearings if damaged. Mount bearing puller on pinion, and press pinion from bearing. Remove pinion shim located behind bearing. Measure and record shim thickness.
    7. NOTE: DO NOT remove pinion bearing cups unless damaged. If bearing cups are replaced, bearings must also be replaced.
  7. Bearing cups in axle housing may be removed using brass drift and hammer. Tap alternately on each side of bearing cup during removal to prevent bearing cup from binding in axle housing.
  8. If ring gear runout exceeds specification, install differential case with bearings and cups in axle housing without pinion assembly. Install a .265" (6.73 mm) shim on left side of differential case. Install left bearing cap, and finger tighten bolts.
  9. Apply pressure on ring gear toward left side to ensure bearing has seated in cup. Shim right side until slight drag is felt. Install bearing cap and bolts. Tighten bolts to 70-90 ft. lbs. (95-122 N.m). Rotate differential case to ensure free rotation.
  10. Install dial indicator, and check ring gear runout. If runout is within specification, excessive runout was caused by improper bearing preload. If runout is still excessive, remove differential case.
  11. Mark ring gear and differential case for reassembly reference. Remove ring gear bolts. Tap ring gear from differential case. Install differential assembly in axle housing as in step  8 .
  12. Recheck runout on differential case flange. If runout is within the specification, install NEW ring gear and pinion. See AXLE ASSEMBLY SPECIFICATIONS  . If runout is not within specification, inspect differential case and bearings for damage.
  13. If bearings are not damaged, replace differential case and bearings. Remove differential side bearings using a puller. Mark differential case and ring gear for reassembly reference. Remove pinion gears, side gears, and thrust washers.
RENDER: 1.0x

NO RELATED

Recommended Tools & Savings

Use the Manual With the Right Hardware

Pair factory procedures with proven DIY tools so the instructions are easier to execute.

Affiliate disclosure: We may earn a commission at no extra cost to you.

Shop Manual-Ready ToolsFree Quote CheckQuote Shield Pro

When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.