F 250 4WD Pickup V8-7.3L DSL Turbo VIN K (1994)
10. Remove and tag selective shims located on each side of differential bearing bore to indicate side of carrier from which they were removed. Inspect
shims for damage, bending or deep grooves. If damaged, replace during reassembly procedure.
11. Turn nose of carrier upward, hold end yoke with tool No. T57T-4851-B, or equivalent, then remove pinion nut and washer from pinion assembly.
12. Using yoke remover tool No. T77F-4220-B1, or equivalent, remove end yoke. If yoke shows any sign of wear in seal contact area, replace yoke.
13. Remove drive pinion by tapping on drive pinion shaft using a rawhide or plastic hammer. Catch pinion to prevent damage to pinion teeth. Use care
not to damage pinion bearing preload shims located on the splined end of pinion. If damaged, replace with shims of equal thickness. Do not lose
shims.
WARNING: Gear teeth may have sharp edges, use care when handling gear to prevent personal injury.
14. Using bearing cup puller tool No. T77F-1102-A, or equivalent, and a suitable slide hammer, remove drive pinion oil seal from carrier.
15. Remove outer pinion bearing and oil slinger from carrier input bore.
16. Remove pinion bearing preload shims. Ensure all shims are removed from the carrier. Replace any damaged shims. Shims are available in
thicknesses of 0.003, 0.005, 0.010 and 0.030 inch.
17. Remove inner pinion bearing cup and baffle using a suitable pinion bearing cup remover and driver handle. Pass bearing cup remover and drive
handle through outer bearing cup and place against inner bearing cup, then drive inner bearing cup out of bore. Use care not to damage oil baffle
when removing inner bearing cup.
18. Remove oil baffle from inner bearing cup bore. Oil baffle is located between the inner bearing cup and carrier bore. Shims are located between the
inner bearing cup and baffle. Do not damage the shims when removing the bearing cup.
NOTE: If any shims are damaged, measure the thickness and replace with shims of equal thickness.
19. Turn nose of carrier downward and remove outer pinion bearing cup using a suitable pinion bearing cup remover and driver handle. Pass bearing
cup remover and drive handle through inner bearing cup bore and place against outer bearing cup, then drive outer bearing cup out of bore.
20. Remove differential case bearings and shims from case. Position step plate tool No. D80L-630-4, or equivalent, under bearing, then install
universal bearing remover tool No. D81L-4220-A, or equivalent, and remove bearing. Turn case over and remove other bearing in the same
manner.
21. Wire shims, bearing cup and cone together and identify from which side of differential case they were removed.
NOTE: If any shims are damaged, replace with new shims. It is recommended that bearings be replaced.
22. Place a few shop towels over a vise to prevent ring gear teeth from being nicked after it is free from case assembly. Remove ring gear bolts. Tap
ring gear with a rawhide or plastic hammer to free it from case. Remove case and ring gear from vise.
NOTE: Whenever removing ring gear bolts, discard and replace with new bolts upon assembly.
23. Remove bearing and oil slinger from drive pinion using tool No. D81L-4220-A, or equivalent. For controlling drive pinion depth, an oil slinger
with a selective thickness is used.
NOTE: If oil slinger is damaged, measure thickness and replace with a slinger of equal thickness.
24. Inspect all parts for damage and replace as required.
Model 44-IFS-HD
1. Remove axle assembly from vehicle, please refer to Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle
Shaft/Service and Repair/ See: Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair
2. Loosen bolts retaining carrier to axle arm and drain fluid.
3. Remove right hand slip yoke and stub shaft.
4. Remove bolts attaching support arm to carrier, then the carrier assembly.