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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 >> Removal

Differential Ring And Pinion - 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.
  1. Remove the differential carrier. For additional information, refer to DIFFERENTIAL CARRIER - DANA 60 .
    2. NOTE: Index-mark the driveshaft to the pinion flange to maintain correct driveline balance.
    Fig 1: Locating Driveshaft Flange Bolts
    G04644271
  2. Remove and discard the 4 driveshaft flange bolts. Position the driveshaft aside.
  3. Using the special tool to prevent the flange from turning, remove and discard the pinion nut and washer.
    Fig 2: Holding Pinion Flange With Special Tool
    G03919131
  4. Using the special tool, remove the pinion flange.
    Fig 3: Removing Pinion Flange
    G04644273
  5. Using a soft-faced hammer, tap the pinion through the outer bearing. Remove the pinion through the rear of the differential housing.
    • Discard the pinion, bearing and collapsible spacer.
      Fig 4: Removing Pinion
      G03883493
  6. Using the special tools, remove the pinion seal. Discard the seal.
    Fig 5: Removing Pinion Seal Using Special Tools
    G03883494
  7. Remove the oil slinger and the differential pinion bearing.
    Fig 6: Locating Oil Slinger And Differential Pinion Bearing
    G03919135
  8. Using a suitable tool, remove the outer pinion bearing cup, the inner pinion bearing cup and the oil baffle.
    • Use 205-D055 and 205-D051 to remove the inner pinion bearing cup.
    • Use 205-D055 and 205-D054 to remove the outer pinion bearing cup.
  9. Place the differential carrier into a vise with soft jaws.
  10. Using the special tool, remove the differential bearings.
    Fig 7: Removing Differential Bearings Using Special Tool
    G03883484
  11. Remove the differential bearing shims.
    • Wire the shims together and mark from which side they were removed.
      Fig 8: Locating Differential Bearing Shims
      G04644278
    12. CAUTION: Place shop towels under the ring gear to prevent ring gear damage.
    NOTE: Discard the bolts after removing them from the differential case.
  12. Remove the ring gear.
    • Remove and discard 8 of the 12 ring gear bolts. Leave 4 loosely assembled bolts spaced equally apart from each other.
    • Tap each of the 4 bolt heads alternately with a soft face hammer to loosen the ring gear. Remove the 4 bolts and the ring gear. Discard the bolts.
      Fig 9: Tapping Loosley Installed Bolts To Remove Ring Gear
      G03883486
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