Differential Case and Ring Gear - Conventional: Disassembly

All axles 

1. Remove the differential carrier. For additional information, refer to Differential Carrier - Dana 60  or Differential Carrier - Dana 70 .
NOTE: Differential bearing shims are available in thicknesses of 0.762, 0.787, 0.813, 0.838, 0.864, 0.889 and 0.914 mm (0.030, 0.031, 0.032, 0.033, 0.034, 0.035 and 0.036 in).
NOTE: If differential bearing shims are damaged, install new ones.
NOTE: Install new differential bearings whenever they are removed from the rear axle differential carrier.
2. Using the Drive Pinion/Differential Carrier Puller, remove the differential bearings.
   • Wire the differential bearing shims, differential bearing cup, differential bearing and outboard selective spacer together. Note from which side they were removed (ring gear side or opposite side).
Fig 1: Removing Differential Bearings Using Drive Pinion/Differential Carrier Puller
Courtesy of FORD MOTOR CO.
NOTE: Use a vise with brass jaws or wood blocks.
3. Place the differential case in a vise.
NOTE: Whenever removing the ring gear bolts, always install new bolts upon assembly. Use Grade 9 bolts for service replacement for all Dana rear axles.
4. Remove the bolts on the ring gear. Leave 4 bolts loosely assembled, 90 degrees apart.
Fig 2: Identifying Bolts On Ring Gear
Courtesy of FORD MOTOR CO.
5. Tap each bolt head alternately with a rawhide or plastic hammer to loosen the ring gear. Remove the bolts and the ring gear.
Fig 3: Tapping Each Bolt Head Alternately With A Rawhide Or Plastic Hammer To Loosen Ring Gear
Courtesy of FORD MOTOR CO.

Full-float axles 

NOTE: Use a vise with brass jaws or wood blocks.
6. Place the differential case in a vise. Using a small drift, drive out the differential pinion shaft lock pin that secures the differential pinion shaft.
Fig 4: Driving Out Differential Pinion Shaft Lock Pin That Secures Differential Pinion Shaft Using A Small Drift
Courtesy of FORD MOTOR CO.

Semi-float axles 

NOTE: The semi-float axle differential assembly is equipped with either a Loctite® coated differential pinion shaft lock screw or a differential pinion shaft lock screw with torque prevailing threads. The Loctite® treated differential pinion shaft lock screw has a 5/32-in hexagram socket head. Never, under any circumstance, reuse a Loctite® coated screw after removing it. Always discard the screw and install a new one. The torque prevailing differential pinion shaft lock screw has a 12-point drive head. This type of screw is reusable for no more than 4 installations. When in doubt of the number of installations of a torque prevailing differential pinion shaft lock screw, discard it and install a new one or damage to the component may occur.
7. Remove the differential pinion shaft lock screw.

All axles 

8. Using a drift, remove the differential pinion shaft.
Fig 5: Differential Pinion Shaft
Courtesy of FORD MOTOR CO.
9. To remove the differential side gears and the differential pinion gears, rotate the differential side gears. The differential pinion gears will turn to the opening of the differential case.
Fig 6: Differential Side Gears & Differential Pinion Gears
Courtesy of FORD MOTOR CO.
10. Remove the differential pinion gears and the differential pinion gear thrust washers behind the differential pinion gears.
11. Lift out the differential side gears and the differential side gear thrust washers.