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Axle Assembly: Disassembly

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  1. Raise the vehicle on a hoist or raise the rear end of the vehicle with a jack. Install safety stands under the frame rails and lower the jack or hoist enough to allow the rear axle to drop into the rebound position for working clearance. For additional information, refer to JACKING & LIFTING .
  2. Remove the differential housing cover and drain the lubricant.
    • Clean the gasket material from the differential housing cover and the differential housing.
    3. NOTE: An inspection can find the cause of the concern and determine the resolution.
    Fig 1: Checking Differential Ring Gear And Pinion Teeth
    G02760652Courtesy of FORD MOTOR CO.
  3. Carry out the following before disassembly.
    • Remove all the lubricant from the internal parts of the differential assembly. Visually inspect the parts for wear and damage.
    • Rotate the differential assembly to check for any roughness, indicating damaged bearings or gears.
    • Check the differential ring gear and pinion teeth for signs of scoring, abnormal wear, nicks and chips.
    • Use a magnet to search for heavy metal particles indicating component damage.
    4. CAUTION: The differential ring gear and pinion must be clean and dry to obtain an accurate reading.
    Fig 2: Measuring Differential Ring Gear And Pinion Backlash
    G02760653Courtesy of FORD MOTOR CO.
  4. Using the special tools, measure the differential ring gear and pinion backlash at three equally spaced points.
    • The backlash tolerance is 0.13-0.20 mm (0.005-0.008 inch) and cannot vary more than 0.05 mm (0.002 inch) between points checked. A backlash variation of more than 0.05 mm (0.002 inch) indicates gear/case runout.
    • Make corrections for high or low backlash during assembly by changing the differential bearing selective shim thickness.
  5. Remove the axle shafts. For additional information, refer to WHEEL HUBS & BEARINGS-FULL FLOATING AXLE-DANA for full-floating axle shafts, or refer to AXLE SHAFT - SEMI-FLOATING AXLE .
  6. To maintain driveline balance, index-mark the driveshaft flange yoke and the pinion flange.
    Fig 3: Index-Marking Driveshaft Flange Yoke And Pinion Flange
    G02760654Courtesy of FORD MOTOR CO.
  7. Remove the four bolts.
    Fig 4: Removing Driveshaft Flange Bolts
    G02760655Courtesy of FORD MOTOR CO.
    8. CAUTION: The driveshaft flange yoke fits tightly on the pinion flange yoke. Never hammer on the driveshaft or any of its components to disconnect the yoke from the flange. Pry only in the area shown, with a suitable tool, to disconnect the yoke from the flange.
    Fig 5: Disconnecting Driveshaft Flange Yoke From Pinion Flange
    G02760656Courtesy of FORD MOTOR CO.
  8. Using a suitable tool as shown, disconnect the driveshaft flange yoke from the pinion flange and support the driveshaft using mechanic's wire.
    9. CAUTION: Note the positions of the mating letters stamped vertically and horizontally on the bearing caps and the differential housing before removing the bearing caps. Matching the letters is important at the time of assembly.
    Fig 6: Removing Differential Bearing Cups
    G02760657Courtesy of FORD MOTOR CO.
  9. To ease removal of the differential assembly, loosen the bolts, then pry the differential case, bearing cups and outboard spacers outward until they are loose in the differential housing.
  10. Remove the bolts and the bearing caps.
    11. CAUTION: Do not spread the differential housing more than specified.
    Fig 7: Spreading Differential Housing To Specification
    G02760658Courtesy of FORD MOTOR CO.
  11. Using the special tools, spread the differential housing to the specification. Remove special tool 100-D002 after spreading the housing.
    12. CAUTION: It will be necessary to use large pry bars to remove the differential assembly from the differential housing. Do not damage the differential ring rear when carrying out this step.
    CAUTION: Mark or tag the differential bearing cups, indicating from which side they were removed.
    Fig 8: Removing Differential Assembly With Bearing Cups
    G02760659Courtesy of FORD MOTOR CO.
  12. Remove the differential assembly with the bearing cups.
    • Inspect the differential bearing cups for deep scores, galling and spalling. Discard them if necessary.
    13. CAUTION: Mark or tag the outboard spacers indicating from which side they were removed.
    Fig 9: Removing Outboard Spacers
    G02760660Courtesy of FORD MOTOR CO.
  13. Remove the outboard spacers.
    • Inspect the spacers for nicks, bending and grooved conditions. Discard them if necessary.
    14. NOTE: Use a vise with brass jaws or wood blocks.
  14. Place the differential case in a vise.
    15. 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.
    Fig 10: Identifying Ring Gear
    G02760661Courtesy of FORD MOTOR CO.
  15. Remove the bolts on the ring gear. Leave four bolts loosely assembly, 90 degrees apart.
  16. Tap each bolt head alternately with a rawhide or plastic hammer to loosen the ring gear. Remove the bolts and the ring gear.
    Fig 11: Removing Ring Gear
    G02760662Courtesy of FORD MOTOR CO.
  17. If required, remove the anti-lock speed sensor ring with a soft-faced hammer. Discard the anti-lock speed sensor ring.
    Fig 12: Removing Anti-Lock Speed Sensor Ring
    G02760663Courtesy of FORD MOTOR CO.
    18. NOTE: Special tool removed for clarity.
    Fig 13: Installing Differential Bearing Caps
    G02760664Courtesy of FORD MOTOR CO.
  18. Install the differential case.
    1. Position the differential case assembly, including bearing clips and shims, in the differential housing.
    2. Install the differential bearing caps.
    3. Install the differential bearing bolts.
      • Loosen the special tool.
  19. Position the special tool.
    1. Rotate the differential case to make sure the differential bearings are correctly seated.
    2. Install the special tool.
    Fig 14: Installing Special Tool
    G02760665Courtesy of FORD MOTOR CO.
    20. NOTE: If runout is within specification, install a new ring gear and pinion. If runout exceeds specification, the ring gear is true and the concern is due to either a damaged differential case or differential bearings. Inspect the differential bearings. If the differential bearings are not damaged, install a new differential case and the differential bearings.
    Fig 15: Measuring Differential Case Runout Without Ring Gear
    G02760666Courtesy of FORD MOTOR CO.
  20. Measure the differential case runout without the ring gear.
    1. Rotate the differential case.
    2. Check and note the differential case runout.
  21. Remove the differential assembly with the bearing cups.
    22. CAUTION: Index-mark the pinion flange to the pinion shaft prior to removal.
    Fig 16: Removing Lock Nut And Washer
    G02760667Courtesy of FORD MOTOR CO.
  22. Use the special tool to prevent the flange from turning while removing the lock nut and washer.
  23. Using the special tool, remove the pinion flange.
    Fig 17: Removing Pinion Flange
    G02760668Courtesy of FORD MOTOR CO.
    24. NOTE: There are drive pinion bearing preload shims and, on Model 70 axles, a preload spacer on the spline-end of the pinion. These shims and spacer can stick to the pinion, the pinion bearing, or they can fall out of the differential housing. Collect and keep the shims and spacer for reassembly.
    Fig 18: Removing Pinion Out Of Pinion Bearing Cup
    G02760669Courtesy of FORD MOTOR CO.
  24. Using a soft-face hammer, tap the pinion out of the pinion bearing cup and remove it through the rear of the differential housing.
  25. Using the special tools, remove and discard the pinion seal.
    Fig 19: Removing Pinion Seal
    G02760670Courtesy of FORD MOTOR CO.
  26. Remove the oil slinger and the pinion bearing.
    27. CAUTION: Do not nick the differential housing bore.
    Fig 20: Removing Outer Pinion Bearing Cup
    G02760671Courtesy of FORD MOTOR CO.
  27. Using the special tools, remove the outer pinion bearing cup.
    • For Model 60/70 axles, use tools 205-D054 and 205-D055.
  28. Using the special tools, remove the inner pinion bearing cup.
    • For Model 60 axles, use tools 205-D051 and 205-D055.
    • For Model 70 axles, use tools 205-D052 and 205-D055.
    Fig 21: Removing Inner Pinion Bearing Cup
    G02760672Courtesy of FORD MOTOR CO.
  29. Using the special tool, remove the inner pinion bearing.
    Fig 22: Removing Inner Pinion Bearing
    G02760673Courtesy of FORD MOTOR CO.
    30. NOTE: Discard the drive pinion position shim if bent or nicked. If discarding the shim, measure and record the shim thickness.
  30. Remove the drive pinion position shim.
  31. Carry out the following after disassembling the axle:
    • Thoroughly clean all parts.
    • Inspect all parts for damage and wear.
    • Clean the inside of the differential case before assembly.
      • Thoroughly clean the differential housing if the gears have scores/chips in them.
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