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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1542 (Front Drive Axle/Differential -- F250-F550 Super Duty) >> Removal And Installation >> Differential Ring And Pinion - Dana 60 >> Installation

Differential Ring And Pinion - 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.
    NOTE: Apply Threadlock and Sealer to the 12 new bolts.
    Fig 1: Locating Threadlock And Sealer Bolts
    G04644280
  1. Start 2 new bolts through the differential case flange and into the differential ring gear to make sure the differential ring gear and the differential case align.
  2. Install the remaining 10 new ring gear bolts and draw up the new ring gear bolts alternately and evenly.
    • Tighten to 183 Nm (135 lb-ft).
      Fig 2: Identifying Ring Gear
      G03883485
  3. Place the special tool on the differential case hubs and position the assembly into the differential housing.
    Fig 3: Positioning Differential Case With Special Tool
    G03919145
    4. NOTE: Repeat this step until there is a consistent reading.
    Fig 4: Placing Special Tool
    G04644283
    Fig 5: Identifying Special Tool
    G04644284
  4. Force the differential case as far as possible toward the indicator. With force applied, set the indicator at 0. Force the differential case as far as it will go in the opposite direction. Record the total differential case end play reading.
  5. Remove the differential case with the special tool from the differential housing.
    • Do not remove the special tool from the differential case hubs.
      Fig 6: Positioning Differential Case With Special Tool
      G03919145
    6. NOTE: Make sure the inner oil baffle is squarely under the inner pinion bearing cup.
  6. Install the inner oil baffle and the inner and outer pinion bearing cups.
  7. Using the special tools, install the pinion bearing cups.
    • Place the special tools on the inner and outer bearing cups.
      • Place special tool 205-006-B1 on the outer pinion bearing cup.
      • Place special tool 205-006-B2 on the inner pinion bearing cup.
    • Install and tighten special tool 205-098 to seat the cups.
      Fig 7: Installing Special Tool
      G04644286
    8. NOTE: If the feeler gauge can fit between a cup and the bottom of its bore at any point around the cup, remove and reseat the cup.
    Fig 8: Checking Clearance Between Cup And Bore
    G03878664
  8. Check that the cups have seated correctly in their bores.
    9. NOTE: If any of the gauge surfaces have nicks in them, remove the high spots with a medium India oilstone to prevent erroneous readings.
    NOTE: Apply only a light oil film on the pinion bearings before assembling the tools.
  9. Assemble and position the following in the differential housing in the following sequence:
    1. Position the adapter 205-160.
    2. Position the adapter 205-105.
    3. Position the inner pinion bearing.
    4. Position the adapter 205-125.
    5. Position the adapter 205-159.
    6. Position the outer pinion bearing.
    7. Thread on the adapter 205-111.
      Fig 9: Identifying Pinion Bearings & Special Tools
      G03883577
    10. NOTE: This step simulates pinion bearing preload.
  10. Using a Nm (lb-in) torque wrench, tighten the special tool to set the rotational torque.
    • Tighten to a rotational torque of 2.2 Nm (20 lb-in).
      Fig 10: Checking Differential Pinion Bearing Preload
      G03878601
    11. NOTE: Offset the special tool to obtain an accurate reading.
    Fig 11: Rotating Special Tool
    G03883649
  11. Rotate the special tool several half-turns to seat the pinion bearings. Position the special tool as shown.
  12. Install the special tool.
    1. Install the 2 bearing caps.
    2. Install the 4 bolts.
      • Tighten to 108 Nm (80 lb-ft).
        Fig 12: Installing Bearing Caps And Bolts
        G04644291
    13. NOTE: Use a feeler gauge or flat, clean drive pinion position shims as a measuring device.
    NOTE: Do not attempt to force the gauge or shim between the special tools. A slight drag indicates a correct selection.
  13. Using a feeler gauge or flat, clean drive pinion position shims, measure the gap between the special tools. Record the measurement.
    • Remove the special tools after making the correct shim selection.
      Fig 13: Locating Drive Pinion Shims
      G04644292
  14. Notice the (+) or (-) etching on the pinion, and adjust the new shim thickness to compensate for the difference of these 2 figures.
    • For example, a pinion etched with m+8 (+3) requires 0.08 mm (0.003 in) less shimming than a pinion etched "0". This means to increase the mounting distance by the amount etched in the pinion, subtract 0.08 mm (0.003 in) from the drive pinion position shim selected for installation. A pinion etched m-8 (-3), requires 0.08 mm (0.003 in) more shimming than a pinion etched "0". In this instance, add 0.08 mm (0.003 in) to the drive pinion position shim selected for installation to decrease the pinion mounting distance by the amount etched in the pinion.
      Fig 14: Identifying Numbers On Pinion & Ring Gear
      G03883411
    15. CAUTION: Follow the drive pinion bearing preload shim and drive pinion position shim assembly sequence as directed or unit failure can result.
  15. Install the correct thickness drive pinion position shim on the pinion.
    • To change the pinion adjustment, drive pinion position shims are available in the thickness shown in the following charts. Measure each shim separately with a micrometer.
    AVAILABLE DRIVE PINION POSITION SHIMS

    mm Inch
    1.22 0.048
    1.27 0.050
    1.32 0.052
    1.37 0.054
    1.42 0.056
    1.47 0.058
    1.52 0.060
    1.57 0.062
  16. Using the special tools, install the differential pinion bearing.
    Fig 15: Installing Differential Pinion Bearing Using Special Tools
    G03883514
  17. Using a suitable driver, install the pinion seal.
    • Lightly coat the pinion seal lip with lubricant.
      Fig 16: Driving Pinion Seal Into Housing Using Special Tool
      G04643595
  18. Install a new collapsible spacer.
    Fig 17: Locating Collapsible Spacer
    G03919137
    19. CAUTION: Do not damage the pinion, the bearings, the seal or the cup.
    Fig 18: Locating Inner Bearing Into Bearing Cup
    G04644297
  19. Insert the pinion into the differential housing, and seat the inner bearing into the bearing cup.
    20. NOTE: Never use a metal hammer on the pinion flange or install the flange with power tools. If necessary, use a plastic hammer to tap on a tight fitting flange while holding the backside of the drive pinion.
    Fig 19: Identifying Pinion Flange
    G03919090
  20. Lightly coat the flange splines and seal mating area with lubricant, then install the flange and a new washer and pinion nut.
    21. NOTE: Never back off the pinion nut to reduce preload. If preload reduction is necessary, install a new collapsible spacer and pinion nut.
  21. Tighten the nut.
    • Use the special tool to prevent the flange from turning while tightening the nut. Remove the special tool when taking pinion bearing torque preload readings.
    • Rotate the pinion occasionally to verify that the bearings are seating correctly.
    • Take frequent pinion bearing torque preload readings.
      Fig 20: Holding Pinion Flange With Special Tool
      G03919131
  22. Tighten to a rotational torque of 1.7-3.4 Nm (15-30 lb-in).
    Fig 21: Measuring Pinion Bearing Torque Preload
    G03919085
  23. Position the differential case with the special tool into the differential housing.
    Fig 22: Positioning Differential Case With Special Tool
    G03919145
    24. NOTE: Repeat this step until there is a consistent reading.
  24. Using the special tools, determine the total thickness of differential bearing shims to install under the differential bearing on the ring gear side of the differential case. Record this measurement, as the shim thickness required for the ring gear side of the differential case.
    • Force the ring gear away from the pinion and zero the special tool.
    • Force the ring gear into mesh with the pinion.
      • Rock the ring gear to allow the teeth of the gears to mesh.
    • Record the reading.
      Fig 23: Identifying Special Tool
      G04644302
  25. Remove the differential case and the special tool from the differential housing.
    • Remove the special tool from the differential case.
      Fig 24: Positioning Differential Case With Special Tool
      G03919145
  26. Place the required thickness of differential bearing shims on the ring gear side of the differential case. Refer to the measurement recorded, as the shim thickness required for the ring gear side of the differential case. Differential bearing shims are available in the thickness shown in the following chart.
    • For example, a reading of 1.14 mm (0.045 in), requires that 1.14 mm (0.045 in) shims be placed on the ring gear side of the differential case.
    AVAILABLE DIFFERENTIAL BEARING SHIMS

    mm Inch
    0.076 0.003
    0.127 0.005
    0.254 0.010
    0.762 0.030
  27. Using the special tool(s), install the differential bearing.
    Fig 25: Identifying Special Tool For Differential Bearing Installation
    G03883526
  28. Determine the total thickness of differential bearing shims to install under the differential bearing on the drive pinion side of the differential case.
    • Subtract the measurement recorded, as the shim thickness required for the ring gear side of the differential case, from the total case end play measurement taken at the beginning of the assembly procedure. Then, add 0.38 mm (0.015 in) to the total. This is the total amount of differential bearing shims to install under the differential bearing on the drive pinion side of the differential case.
  29. Place the amount of differential bearing shims, as determined by the calculation made in the previous step, on the drive pinion side of the differential case.
  30. Using the special tools, install the differential bearing.
    1. Place the special tool under the bearing to protect it during the bearing installation.
    2. Using the special tool, install the bearing.
      Fig 26: Installing Differential Bearing
      G03883589
  31. Position the differential bearing cups on the bearings.
    Fig 27: Locating Differential Bearing Cups On Bearings Position
    G04644306
    32. 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.
    NOTE: Use a safety strap to keep the C-clamp from rotating.
    NOTE: Use a C-clamp with a minimum 15 inch opening and a 16,250 lb load limit.
  32. Using a C-clamp with the dial indicator, spread the differential housing 0.38 mm (0.015 in) and install the differential carrier.
    • Remove the dial indicator after measuring the housing spread.
    • Using a soft-faced hammer, seat the differential into the differential housing.
      • Remove the C-clamp after seating the differential in the differential housing.
        Fig 28: Removing C-Clamp
        G04644307
    33. NOTE: Match the positioning of the mating letters on the bearing caps and the differential housing.
  33. Install the 2 bearing caps and the 4 bolts.
    • Tighten to 108 Nm (80 lb-ft).
      Fig 29: Locating Differential Bearing Caps
      G04414224
  34. Using the special tools, measure backlash at 3 equally spaced points.
    • The backlash must be within the specifications, and cannot vary more than 0.05 mm (0.002 in) between points checked.
    • Make the necessary corrections by moving shims from one side of the differential case to the other, until the correct backlash adjustment is achieved.
    • Correct for low backlash by moving the ring gear away from the pinion.
    • Correct for high backlash by moving the ring gear toward the pinion.
      Fig 30: Identifying Special Tool
      G04644309
  35. Apply marking compound and rotate the differential assembly 5 complete revolutions.
  36. Verify an acceptable pattern check. For additional information, refer to DRIVELINE SYSTEM-GENERAL INFORMATION .
    37. NOTE: Clean the differential housing cover mounting surfaces with a suitable solvent to remove all traces of oil film or foreign material.
    NOTE: Install the differential housing cover within 15 minutes of applying the silicone material.
    Fig 31: Locating Differential Housing Cover Sealant
    G04414153
  37. Apply the specified bead of silicone rubber sealer as shown.
    38. 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.
  38. Install the differential housing cover and the 10 differential cover bolts.
    • Tighten to 47 Nm (35 lb-ft).
      Fig 32: Identifying Differential Housing Cover Bolt
      G03883433
  39. Position the driveshaft in the front axle flange. Install the 4 new flange bolts.
    • Tighten to 35 Nm (26 lb-ft).
  40. Install the axle shaft assemblies and the front wheel hubs. For additional information, refer to FRONT SUSPENSION - FOUR WHEEL DRIVE (4WD) .
    41. NOTE: If possible, allow one hour curing time before filling the axle with lubricant.
  41. Fill the axle with the specified type and quantity of lubricant.
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