Ford F150 Pickup. Instruction - part 545

Fig. 160: Installing Special Tool In Bottom Side Gear Bore 
Courtesy of FORD MOTOR CO. 

5. Install the special tool in the bottom side gear bore.  

6. Install the nut in the upper differential side gear. Hold the nut in position while installing the hex screw. 

Tighten the hex-head screw until contact is made with the Step Plate. 

 

2003 Ford Pickup F150 

2003 DRIVELINE/AXLES Rear Drive Axle/Differential - Ford 10.25-inch - F150 Pickup

  

Fig. 161: Installing Nut In Upper Differential Side Gear 
Courtesy of FORD MOTOR CO. 

7. Insert a suitable dowel bar in the hole of the nut. Tighten the forcing screw to force the differential side 

gear away from the differential pinion gears. The dowel bar is used to keep the nut from turning when the 
forcing screw is tightened. 

 

2003 Ford Pickup F150 

2003 DRIVELINE/AXLES Rear Drive Axle/Differential - Ford 10.25-inch - F150 Pickup

  

 

2003 Ford Pickup F150 

2003 DRIVELINE/AXLES Rear Drive Axle/Differential - Ford 10.25-inch - F150 Pickup

  

Fig. 162: Inserting Suitable Dowel Bar In Hole Of Nut
Courtesy of FORD MOTOR CO. 

Fig. 163: Inserting Special Tool In Pinion Shaft Bore 
Courtesy of FORD MOTOR CO. 

8. Inserting the special tool in the pinion shaft bore, turn the differential case to "walk" the differential 

pinion gears and differential pinion thrust washers out to the differential case windows.  

WARNING:

Keep fingers/hands away from pinion gears when rotating the 
differential case with the differential rotating tool.

NOTE:

Differential pinion thrust washers (4230) cannot be removed independently 
of the differential pinion gears and so must be removed simultaneously 
with the differential pinion gears.

 

2003 Ford Pickup F150 

2003 DRIVELINE/AXLES Rear Drive Axle/Differential - Ford 10.25-inch - F150 Pickup