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REAR END SPECIALIST..THE BEARING IS COMING OF THE PINION SHAFT AND HAS TO BE DRIVEN BACK ON AND SEALED SO IT WILL NOT SLIDE BACK OFF.. HAD SAME ISSUE.. COST AROUND 200.. ALSO MAKE SURE TO GET POSTIVE TRACK DIFF. ADDIVTIVE.
There's not much inside there to see. Beginning at the driveshaf yoke, You have the nut that holds the pinion yoke on, a washer under that, a seal in the housing to keep the lube in, the outer pinion bearing another washer (or spacers, a crush collar and possibly a few more washers, the pinion bearing and the pinion gear itself. The carrier has a bearing on both ends held on to the housing by two end caps. Inside or on the housing you have the ring gear,four pinion gears and a shaft that holds the two free pinion gears in. That shaft has a 5/16 bolt in one end to keep it from sliding out of the carrier. The axles protrude through the two side gears and are retained by two "C" shaped retainers that can be removed only when the cross shaft has been removed. Sounds rather simple but, rebuilding them requires a lot of experience and dial indicators in order to get it right. Reading a gear contact pattern is part art, part science and getting it wrong will result in noise and quick failure. If you have a positraction unit, the posi plates and springs go inside the carrier and are a bit complicated to install without damaging them. There are many end to end differentials you can put under there available cheap from a scrapyard. Only requirement is to get the drum to drum length right and if it's a 4x4 the gear ration must match the one at the other end of the vehicle.On some, you may need to cut the spring mounts off and weld them in the proper places. If you need info on a specific part inside the rear, ask.
For the rear diff., remove the driveshaft, brake drums, diff. cover, remove pinion flange nut, move diff carrier to access side gear retainer bolt and remove bolt, slide side gear pin out and push axles in to remove axle retainers and remove axels. Mark carrier bearing retainers, spin bearing retainers to loosen carrier for removal. Remove carrier, remove pinion out of diff case, then r&r bearings. Any shims should be replaced in their original location for depth and pinion to ring contact.
To do that job correctly involves removing the carrier, re-setting the pinion depth and checking gear patterns for proper engagement. All that requires experience and special tools (like dial indicators) Generally speaking, when any bearing in the differential fails, the debris contaminates the other bearings therefore, even if the outer pinion bearing has failed, inner and both side bearings should be replaced or shortly after the job is finished, you will have another problem. Generally faster and easier to replace the entire unit with a scrapyard part (drum to drum). Just make sure that if it's a 4x4, that you match the gear ratio exactly.Most otherwise decent techs can't set up a differential right so unless you are really into doing this, a replacement is the way to go.
If you want to try just replacing the outer bearing, count the number of turns it took to remove the pinion nut and when putting it back together,re- tighten the nut to that exact number including any half turns. You will need a seal and bearing assembly. You can drive the bearing race out from the inside by removing the carrier and the pinion gear. Carrier bolts need to be torqued. (don't remember the # off hand but it's in any decent manual)
locking differential jack up and support rear of truck drain and remove rear cover remove lock bolt than slide out pinion shaft have someone push in on axle and remove c-lock do 4 both axles w/c-locks out remove axles carefully pry off oil seals-will need bearing puller and installer most auto stores rent or let u borrow them- reinstall new bearings and oil seal carefully install axles not 2 damage new oil seals reinstall c-locks and pull back on axle to lock in place slide in pinion shaft reinstall locking bolt torque to 25 ft-lbs reinstall cover and fill with gear oil
if diying and axle bad replace the whole unit from salvage or rebuild shop.if changing the bearings its a lot of work and you will need some special tools to put back together .first you need to use a lift or again have to remove unit from truck, disconnect battery remove drive shaft,remove pinion nut need large breaker bar loosen bolts to rear cover drain fluid remove cover have someone push axles toward center remove c locks slide out axles best way to remove bearings is slide hammer bearing removal unit remove rear [gears] dont loose shims will see pinion bearing bearing remove and replace now 2 put it back.need shim package, red lead, 4 ring and gear mesh adjustments ,,
Section 05-02A: Axle, Integral Carrier — 8.8-Inch Ring Gear
1994 Town Car, Crown Victoria/Grand Marquis. Workshop Manual
REMOVAL AND INSTALLATION
NOTE: Whenever replacing the rear axle lubricant, use Rear Axle Lubricant XY-90-QL (ESP-M2C154-A) or equivalent. Removal CAUTION: The rear brake anti-lock sensor must be removed before the axle shafts are removed. The rear brake anti-lock sensor is bolted on the rear disc brake caliper anchor plate.
Raise vehicle to desired working height. Refer to Section 00-02 . Remove rear wheel (1007) and tire assembly. Remove rear disc brake calipers (2552) and rear disc brake rotors (2C026) .
Clean all dirt from area of axle housing cover with a wire brush and/or cloth.
Drain rear axle lubricant by removing the axle housing cover .
Push flanged end of the axle shafts toward the center of the vehicle and remove the rear axle shaft retaining u-washer from the button end of the axle shaft .
Remove axle shaft from the rear axle housing , being careful not to damage the inner wheel bearing oil seal (1177) and rear brake anti-lock sensor ring.
Installation NOTE: Check for presence of rear axle shaft o-ring (4A332) on the spline end of the shaft and install if not present. CAUTION: Care must be taken not to let axle shaft splines damage oil seal or bearing assembly.
Carefully slide axle shaft into rear axle housing without damaging rear wheel bearing (1225) or rear brake anti-lock sensor indicator (2C189) . Start splines into side gear and push firmly until the button end of axle shaft can be seen in the differential case .
Install the rear axle shaft retaining u-washer on the button end of the axle shaft splines, then pull the shaft outboard until the shaft splines engage and the rear axle shaft retaining u-washer seats in the counterbore of the differential side gear .
Position the differential pinion shaft through the differential case and differential pinion gears , aligning the hole in the differential pinion shaft with the lock bolt hole. Apply Rear Axle Lubricant to differential pinion shaft lock pin . Install differential pinion shaft lock pin and tighten to 20-41 Nm (15-30 lb-ft).
CAUTION: Differential pinion shaft lock pin must be tightened to specification using Stud and Bearing Mount E0AZ-19554-BA (WSK-M2G349-A1) or equivalent.
NOTE: Axle housing cover must be installed within 15 minutes of application of the silicone rubber or new silicone rubber must be applied. CAUTION: Make sure machined surfaces on both axle housing cover and rear axle housing are clean before installing the new silicone sealant. Inside of axle must be covered when cleaning the machined surface to prevent axle contamination. Tighten the cover bolts in a crosswise pattern to ensure uniform draw on axle housing cover .
Apply Silicone Rubber D6AZ-19562-AA or BA (ESB-M4G92-A or ESE-M4G195-A) or equivalent. Install axle housing cover and tighten retaining bolts to 28-38 Nm (38-52 lb-ft).
Add Motorcraft Rear Axle Lubricant XY-90-QL or KL (ESP-M2C154-A) or equivalent until it is 6-14mm (1/4-9/16 inch) below bottom of fill hole. Add 118.3 mL (4 oz) of Ford Additive Friction Modifier C8AZ-19B546-A (EST-M2C118-A) or equivalent to Traction-Lok axles. Install fill plug and tighten to 20-41 Nm (15-30 lb-ft).
Insert Rear Bearing Remover T85L-1225-AH in bore and position it behind bearing so tangs on tool engage bearing outer race. Remove rear wheel bearing and inner wheel bearing oil seal as a unit, using Impact Slide Hammer T50T-100-A.
Rear Disc Brake Caliper Anchor Plate
Lubricate the rear wheel bearing with Rear Axle Lubricant.
Install rear wheel bearing into the housing bore using Axle Tube Bearing Replacer T78P-1225-A.
CAUTION: Installation of rear wheel bearing or inner wheel bearing oil seal assembly without proper tool may result in an early bearing or seal failure. If inner wheel bearing oil seal becomes cocked in bore during installation, remove it and install a new one.
Install the inner wheel bearing oil seal using Axle Tube Seal Replacer T78P-1177-A. Use Premium Long-Life Grease XG-1-C or K (ESA-M1C75-B) or equivalent between the lips of the inner wheel bearing oil seal .
As a matter of fact the diff can make noise on and off the gas, my own car a 1996 Corvette does this, it needs the ring and pinion replaced, is this what you are talking about when you say they told you that you needed a whole new differential?