Differential Bearings - Dana 60

WARNING: This page is about a different car, the 2004 Ford RV Cutaway, 2004 Ford Econoline, 2004 Ford E450 Super Duty, and 2004 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Special Tools (1 Of 3)

Courtesy of FORD MOTOR CO.

Fig 2: Identifying Special Tools (2 Of 3)

Courtesy of FORD MOTOR CO.

Fig 3: Identifying Special Tools (3 Of 3)

Courtesy of FORD MOTOR CO.

MATERIALS

Item	Specification
Ultra Silicone Sealant F7TZ-19554-AA	-
Additive Friction Modifier C8AZ-19B546-A	EST-M2C118-A
SAE 75W-140 High Performance Rear Axle Lubricant XY-75W140-QL (vehicles with the trailer towing option or 4:10 ratio)	WSL-M2C192-A
80W-90 Premium Rear Axle Lubricant XY-80W90-QL (Model 60/70 axles)	WSP-M2C197-A
Threadlock and Sealer E0AZ-19554-AA	WSK-M2G351-A5

Remove the differential carrier assembly. For additional information, refer to DIFFERENTIAL CARRIER -DANA 60 .

NOTE: Wire tag the removed outboard spacers. Note from which side they were removed.

Fig 4: Removing Differential Bearings

Courtesy of FORD MOTOR CO.

Using the special tools, remove the differential bearings.
- Place the left and right differential bearing shims with the respective outboard spacers.
To maintain driveline balance, index-mark the driveshaft flange yoke and the pinion flange.

Fig 5: Index-Marking Driveshaft Flange Yoke And Pinion Flange
Courtesy of FORD MOTOR CO.
Remove the 4 bolts.

Fig 6: Removing Driveshaft Flange Bolts
Courtesy of FORD MOTOR CO.

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 7: Disconnecting Driveshaft Flange Yoke From Pinion Flange

Courtesy of FORD MOTOR CO.

Using a suitable tool as shown, disconnect the driveshaft flange yoke from the pinion flange and support the driveshaft using mechanic's wire.

CAUTION: Index-mark the pinion flange to the pinion shaft prior to removal.

Fig 8: Removing Lock Nut And Washer

Courtesy of FORD MOTOR CO.

Use the special tool to prevent the flange from turning while removing the lock nut and washer.
Using the special tool, remove the pinion flange.

Fig 9: Removing Pinion Flange
Courtesy of FORD MOTOR CO.

NOTE: There are drive pinion bearing preload shims 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 for reassembly.

Fig 10: Removing Pinion Out Of Pinion Bearing Cup

Courtesy of FORD MOTOR CO.

Using a soft-face hammer, tap the pinion out of the pinion bearing cup and remove it through the rear of the differential housing.
Using the special tools, remove and discard the pinion seal.

Fig 11: Removing Pinion Seal
Courtesy of FORD MOTOR CO.
Remove the oil slinger and the pinion bearing.

CAUTION: Do not nick the differential housing bore.

Fig 12: Removing Outer Pinion Bearing Cup

Courtesy of FORD MOTOR CO.

Using the special tools, remove the outer pinion bearing cup.
- For semi-float axles, use tools 205-D054 and 205-D055.
Using the special tools, remove the inner pinion bearing cup.
- For semi-float axles, use tools 205-D051 and 205-D055.
Fig 13: Removing Inner Pinion Bearing Cup
Courtesy of FORD MOTOR CO.
Using the special tool, remove the inner pinion bearing.

Fig 14: Removing Inner Pinion Bearing
Courtesy of FORD MOTOR CO.

NOTE: Discard the drive pinion position shim if bent or nicked. If discarding the shim, measure and record the shim thickness.

Remove the drive pinion position shim.
Position the inner and outer pinion bearing cups and the special tools in their respective differential housing bores.
1. After placing the inner and outer pinion bearing cups in their bores, place the special tool (inner) on the inner pinion bearing cup.
2. Place the special tool (outer) on the outer pinion bearing cup.
3. Install the special tool.
Fig 15: Installing Special Tool
Courtesy of FORD MOTOR CO.
Tighten the special tool to seat the pinion bearing cups into their bores.

Fig 16: Tightening Special Tool To Seat Pinion Bearing Cups Into Their Bores
Courtesy of FORD MOTOR CO.

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 17: Checking That Cups Have Seated Correctly In Their Bores

Courtesy of FORD MOTOR CO.

Check that the cups have seated correctly in their bores.
Install the outboard spacers in the side from which they were removed.

Fig 18: Installing Outboard Spacers
Courtesy of FORD MOTOR CO.

NOTE: Remove all nicks, burrs and dirt from the differential case hubs, to allow the bearings to rotate freely.

Fig 19: Placing Special Tool On Differential Case Hubs And Position Assembly Into Differential Housing

Courtesy of FORD MOTOR CO.

Place the special tool on the differential case hubs and position the assembly into the differential housing.
- For semi-float axles, use tool 205-D047.

NOTE: Use a dial indicator with a minimum travel capability of 5.08 mm (0.200 in).

NOTE: The rear axle uses a combination of differential bearing shims and selective outboard spacers to control differential case end play. The old outboard spacers provide a good starting point when setting end play. However, if additional shimming is necessary, beyond what the hardened differential bearing shims can provide, select and install different thickness outboard spacers.

Fig 20: Locating Tip Of Special Tool 308-021 On A Flat Surface Of Bolt

Courtesy of FORD MOTOR CO.

Mount the special tools as shown. Locate the tip of special tool 308-021 on a flat surface on one of the bolts.

NOTE: Repeat this step and the following step until the same reading appears on the indicator each time. Record the reading. This is the total differential bearing shim thickness required, less preload.

Fig 21: Forcing Differential Case As Far As Possible Toward Indicator

Courtesy of FORD MOTOR CO.

The final calculation occurs later during assembly.
Force the differential case as far as possible toward the indicator. With force still 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.

Fig 22: Measuring Total Differential Case End Play
Courtesy of FORD MOTOR CO.
After making sure the reading is correct, remove the special tools and the differential from the differential housing. Do not remove the Master Bearings from the differential case at this time.

Fig 23: Removing Special Tools
Courtesy of FORD MOTOR CO.

CAUTION: 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.

Fig 24: Assembling Special Tool

Courtesy of FORD MOTOR CO.

Assemble and position the following in the differential housing.
1. Position the special tool.
2. Position the special tool.
3. Position the inner pinion bearing.
4. Position the special tool.
5. Position the special tool.
6. Position the outer pinion bearing.
7. Thread on the special tool.
Install the special tool.
1. Position the special tool.
  - For semi-float axles, use tool 205-D033.
2. Install the bearing caps.
3. Install the bolts.
  - Tighten to 108 Nm (80 lb-ft).
Fig 25: Installing Bearing Caps
Courtesy of FORD MOTOR CO.

NOTE: Use a feeler gauge or flat, clean drive pinion position shims as a measuring devise.

NOTE: Do not attempt to force the gauge or shim between the special tools. A slight drag indicates a correct selection.

Fig 26: Removing Special Tools After Making Correct Shim Selection

Courtesy of FORD MOTOR CO.

Using a feeler gauge or flat, clean drive pinion position shims, measure between the special tools. Record the measurement. Refer to PINION RING GEAR VARIATION NUMBER for shim selection information.
- Remove the special tools after making the correct shim selection.

CAUTION: Follow the drive pinion bearing preload shim and drive pinion position shim assembly sequence as directed or unit failure can result.

Install the correct thickness drive pinion position shim on the pinion.
If the pinion bearing preload is within specification and the pinion position shim has changed, change the drive pinion bearing preload shims by the same amount.
- The direction arrow pointing toward the pinion flange indicates that by removing the drive pinion position shim, the distance from the centerline of the tubes to the pinion backface increases, giving a plus (+) reading. The drive pinion bearing preload shim pack does not affect the pinion depth setting. However, if the pinion position is changed, the pinion preload will change and may require adjustment to bring the torque-to-rotate within specification. Arrows on the ring gear illustrate the method to increase or decrease backlash and differential bearing preload.
Fig 27: Arrows On Ring Gear Illustrate Method To Increase Or Decrease Backlash And Differential Bearing Preload
Courtesy of FORD MOTOR CO.

NOTE: Always use the same new inner pinion bearing installed when taking the measurement for drive pinion shim selection.

Fig 28: Installing Pinion Bearing

Courtesy of FORD MOTOR CO.

Using the special tool and a suitable press, install the pinion bearing.
- For semi-float axles, use tool 205-092.

NOTE: Use the thickness of the old drive pinion bearing preload shims as a starting point for setting pinion bearing preload.

Inspect the drive pinion bearing preload shims for damage. Discard them if necessary. New shims are available in the thickness shown in the following chart.

AVAILABLE DRIVE PINION BEARING PRELOAD SHIMS

mm	inches
0.36	0.014
0.38	0.015
0.41	0.016
0.46	0.018
0.51	0.020
0.53	0.021
0.56	0.022
0.58	0.023
0.76	0.030

Assemble the drive pinion bearing preload shims onto the pinion and install the pinion into the differential housing.
Install the outer pinion bearing.
Install the pinion flange.
Use the special tool to prevent the flange from turning while installing the old washer and the lock nut.
- Tighten to 339 Nm (250 lb-ft).
Fig 29: Installing Old Washer And Lock Nut
Courtesy of FORD MOTOR CO.
Using an inch-pound torque wrench, rotate the pinion. The torque must read as specified.
- To increase the preload, remove drive pinion bearing preload shims. To decrease the preload, add shims.
Fig 30: Using An Inch-Pound Torque Wrench To Rotate Pinion
Courtesy of FORD MOTOR CO.
Position the differential carrier assembly with the Master Bearings in the axle housing. Install the special tools and locate the tip of special tool 308-021 on a flat surface.

Fig 31: Locating Tip Of Special Tool 308-021 On A Flat Surface
Courtesy of FORD MOTOR CO.

NOTE: Repeat this step and the following step until the same reading appears on the indicator each time. This is the differential bearing shim thickness necessary between the differential case and the differential bearing on the differential ring gear side of the differential case.

Fig 32: Forcing Differential Case Away From Drive Pinion

Courtesy of FORD MOTOR CO.

Force the differential case away from the drive pinion. With force still applied, set the indicator at 0.
Force the differential ring gear into mesh with the pinion, to obtain an indicator reading. Record the reading.

Fig 33: Forcing Differential Ring Gear Into Mesh With Pinion
Courtesy of FORD MOTOR CO.
Remove the special tools and the differential case from the differential housing.

Fig 34: Removing Special Tools And Differential Case From Differential Housing
Courtesy of FORD MOTOR CO.
Remove the Master Bearings from the differential case.
Place one shim, of the necessary thickness, as determined from the previous measurement, on the LH side of the differential case. If additional shimming is necessary, beyond what the hardened differential bearing shim can provide, select and install a different thickness outboard spacer.
Using the special tool, install the differential bearing on the LH side of the differential case.

Fig 35: Installing Differential Bearing On LH Side Of Differential Case
Courtesy of FORD MOTOR CO.
Determine the correct shim thickness and place it on the differential case hub on the RH side.
- To determine the correct shim thickness, first, subtract the reading of the previous measurement from the total differential case end play reading. Then, add 0.25 mm (0.010 in) to this amount. This is the correct thickness shim to place on the hub. If additional shimming is necessary, beyond what the hardened differential bearing shim can provide, select and install a different thickness outboard spacer.
Using the special tools, install the differential bearing.
1. Place the special tool on the differential bearing to protect it during the installation of the opposite bearing.
2. Using the special tool, drive the differential bearing onto the hub.
Fig 36: Installing Differential Bearing
Courtesy of FORD MOTOR CO.
Assemble the differential bearing cups to the differential bearings.

CAUTION: Do not spread the differential housing more than specified.

CAUTION: Avoid nicking the ring gear teeth and the anti-lock speed sensor ring during assembly.

Fig 37: Spreading Differential Housing To Specification

Courtesy of FORD MOTOR CO.

Using the special tools, spread the differential housing to the specification.
- Use a rawhide hammer to seat the differential into the differential housing pocket.
  - Remove the special tools.

CAUTION: Match the mating letters as noted during disassembly.

Fig 38: Installing Bearing Caps, Aligning Letters With Those On Differential Housing

Courtesy of FORD MOTOR CO.

Install the bearing caps and bolts, aligning the letters with those on the differential housing.
- Tighten to 108 Nm (80 lb-ft).
Confirm the total preload.
- Using an inch-pound torque wrench, check the torque to rotate the pinion. The reading must be higher than the initial reading (taken without the differential case installed) with new bearings installed as recommended by the following:
  - 3.54 and 3.73 = 0.9 Nm (8 lb-in)
  - 4.10 and 4.56 = 0.8 Nm (7 lb-in)
  - 4.63 and 5.13 = 0.8 Nm (7 lb-in)
- If the total preload is too high, remove an equal amount of differential bearing shims from each differential case hub. If the total preload is too low, add an equal amount of differential bearing shims to each differential case hub.
Fig 39: Confirming Total Preload
Courtesy of FORD MOTOR CO.
Using the special tools, measure the differential ring gear and pinion backlash at three equally spaced points.

Fig 40: Measuring Differential Ring Gear And Pinion Backlash
Courtesy of FORD MOTOR CO.
Carry out the tooth contact pattern check to verify the final pinion position is correct. For additional information, refer to REAR DRIVE AXLE AND DIFFERENTIAL .
Install the axle shafts. For additional information, refer to AXLE SHAFT - SEMI-FLOATING AXLE .

CAUTION: The driveshaft flange yoke fits tightly on the pinion flange pilot. To make sure that the yoke seats squarely on the flange, tighten the bolts evenly in a cross pattern as shown.

CAUTION: Install the driveshaft with new bolts. If new bolts are not available, apply sealer to the threads of the original bolts.

Fig 41: Tightening Sequence Of Driveshaft Flange Bolt

Courtesy of FORD MOTOR CO.

Position the driveshaft flange yoke on the pinion flange with the index marks aligned and install the new bolts.
- Tighten to 112 Nm (83 lb-ft).

CAUTION: Clean both flat surfaces (differential housing and differential housing cover) with a suitable solvent to remove all traces of oil film.

CAUTION: Install the differential housing cover within 15 minutes of applying the silicone, or it will be necessary to apply new sealant.

NOTE: The differential housing cover uses silicone rubber sealant as a gasket.

Fig 42: Applying A Continuous Bead Of Silicone Sealant, Of Specified Thickness, To Differential Housing Cover

Courtesy of FORD MOTOR CO.

Apply a continuous bead of silicone sealant, of the specified thickness, to the differential housing cover.
Place 2 bolts into the differential housing cover at the 8 o'clock and 2 o'clock positions. Install the differential housing cover.
- Use the 2 bolts to position the differential housing cover on the differential housing.
Install the remaining bolts. Tighten the bolts alternately and evenly.
- Tighten grade 5 bolts to 47 Nm (35 lb-ft).
- Tighten grade 8 bolts to 61 Nm (45 lb-ft).
- Allow 1-hour cure time before filling the axle with the correct amount of specified lubricant.
Fig 43: Installing Differential Housing Cover Bolt
Courtesy of FORD MOTOR CO.
Fill the axle with the specified type and amount of lubricant. For additional information, refer to SPECIFICATIONS .