Differential Carrier - Dana 60: Removal

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.

Remove the front wheel hubs and the front axle shaft assemblies. For additional information, refer to FRONT SUSPENSION - FOUR WHEEL DRIVE (4WD) .
Remove the cotter pin, retainer cap and the RH outer tie-rod end nut.
- Discard the cotter pin.
Using the special tool, disconnect the RH tie-rod and the drag link. Position the drag link aside.

Fig 1: Disconnecting Tie-Rod End Using Special Tool
Remove the 10 bolts and the differential housing cover. Drain the lubricant.
- Clean the gasket material from the differential housing and the differential housing cover.

NOTE: Prior to removal, note the stamped mating letters positioning on the bearing caps and the differential housing for correct reassembly.

Fig 2: Identifying Bearing Caps And Bolts

Remove the 4 bolts and the 2 bearing caps.

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 3: Spreading Differential Housing
Using a pry bar, remove the differential with the bearing cups.
- Remove the C-clamp after removing the differential.