Differential Carrier - Dana 60: Installation

WARNING: This page is about a different car, the 2006 Ford Pickup, 2006 Ford F550 Super Duty, 2006 Ford F450 Super Duty, and 2006 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: Do not spread the differential housing more than specified or damage to the housing may occur.

NOTE: Install the C-clamp at the 12 and 6 o'clock positions to allow the horizontal spread of the housing. Use a safety strap to restrain the C-clamp from rotation.

NOTE: Use a C-clamp with a minimum 15-inch opening and a 16,250 lb load limit.

NOTE: Lubricate the threads of the forcing screw.

Using a C-clamp and the dial indicator, spread the differential housing 0.38 mm (0.015 in).
- Remove the dial indicator after spreading the differential housing.
  
  Fig 1: Spreading Differential Housing
Using a soft-faced hammer, seat the differential into the differential housing.
- Remove the clamp after seating the differential in the differential housing.

NOTE: Match the positioning of the mating letters on the bearing caps and the differential housing.

Install the 2 bearing caps and the 4 bolts.
- Tighten to 108 Nm (80 lb-ft).
  
  Fig 2: Locating Differential Bearing Caps
Using the special tools, measure backlash at 3 equally spaced points.
- The backlash must be within the specifications 0.13-0.20 mm (0.005-0.008 in) and cannot vary more than 0.05 mm (0.002 in) between points checked.
  
  Fig 3: Measuring Differential Ring Gear Backlash Using Special Tools

NOTE: Clean the differential housing cover mounting surfaces with a suitable solvent to remove all traces of oil film or foreign material.

NOTE: The differential housing cover requires the use of silicone sealant material rather than a gasket.

NOTE: Install the differential housing cover within 15 minutes of applying the silicone material.

Fig 4: Locating Differential Housing Cover Sealant

Apply the specified bead of silicone rubber sealer as shown.

NOTE: Allow one hour curing time before filling the axle with lubricant.

NOTE: Place 2 cover bolts into the differential housing cover at the 2 o'clock and 8 o'clock positions. This will help to position the differential housing cover onto the differential housing.

Install the remaining 8 differential housing cover bolts.
- Tighten to 47 Nm (35 lb-ft).
  
  Fig 5: Identifying Differential Housing Cover Bolt
Install the axle shaft assemblies and the front wheel hubs. For additional information, refer to FRONT SUSPENSION - FOUR WHEEL DRIVE (4WD) .
Fill the axle with the specified type and quantity of lubricant.

CAUTION: Make sure that the nut retainer cap is correctly positioned to allow for cotter pin installation. Do not tighten or loosen the nut to align the retainer cap with the cotter pin hole. Overtightening of the fasteners may result in premature failure of steering linkage components.

Position the RH tie-rod and drag link. Install the tie-rod nut, retainer cap and new cotter pin.
- Tighten to 115 Nm (85 lb-ft).