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Differential Carrier -Dana 70

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Fig 1: Identifying Special Tools
G02760639Courtesy of FORD MOTOR CO.
MATERIALS

Item Specification
Ultra Silicone Sealant F7TZ-19554-AA -
Additive Friction Modifier XL-3 EST-M2C118-A
SAE 75W-140 High Performance Rear Axle Lubricant XY-75W140-QL (Model 70 Trailer A Towing axles) WSL-M2C192-A
80W-90 Premium Rear Axle Lubricant XY-80W90-QL WSP-M2C197-A
  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. Remove the axle shafts. For additional information, refer to AXLE SHAFT - SEMI-FLOATING AXLE .
    4. 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 2: Identifying Positions Of Stamped Mating Letters
    G02760640Courtesy of FORD MOTOR CO.
  4. 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.
  5. Remove the bolts and the bearing caps.
    6. CAUTION: Do not spread the differential housing more than specified.
    Fig 3: Spreading Differential Housing To Specification
    G02760641Courtesy of FORD MOTOR CO.
  6. Using the special tools, spread the differential housing to the specification. Remove special tool 100-D002 after spreading the housing.
    7. 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 4: Removing Differential Assembly With Bearing Cups
    G02760642Courtesy of FORD MOTOR CO.
  7. Remove the differential assembly with the bearing cups.
    • Inspect the differential bearing cups for deep scores, galling and spalling. Discard them if necessary.
    8. CAUTION: Mark or tag the outboard spacers indicating from which side they were removed.
    Fig 5: Removing Outboard Spacers
    G02760643Courtesy of FORD MOTOR CO.
  8. Remove the outboard spacers.
    • Inspect the spacers for nicks, bending and grooved conditions. Discard them if necessary.
  9. Assemble the differential bearing cups to the differential bearings.
    10. CAUTION: Mark or tag the outboard spacers indicating from which side they were removed.
    Fig 6: Installing Outboard Spacers In Their Original Positions
    G02760644Courtesy of FORD MOTOR CO.
  10. Install the outboard spacers in their original positions.
    11. 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 7: Spreading Differential Housing To Specification
    G02760645Courtesy of FORD MOTOR CO.
  11. 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.
    12. CAUTION: Match the mating letters as noted during disassembly.
    Fig 8: Tightening Bearing Caps Bolts
    G02760646Courtesy of FORD MOTOR CO.
  12. Install the bearing caps, aligning the letters with those on the differential housing. Tighten the bolts to specification.
  13. Using the special tools, measure the differential ring gear and pinion backlash at three equally spaced points.
    Fig 9: Measuring Differential Ring Gear And Pinion Backlash
    G02760647Courtesy of FORD MOTOR CO.
  14. 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 .
  15. Install the axle shafts. For additional information, refer to AXLE SHAFT - SEMI-FLOATING AXLE .
    16. 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 10: Applying A Continuous Bead Of Silicone Sealant, Of Specified Thickness, To Differential Housing Cover
    G02760648Courtesy of FORD MOTOR CO.
  16. Apply a continuous bead of silicone sealant, of the specified thickness, to the differential housing cover.
  17. Place two bolts into the differential housing cover at the 8 o'clock and 2 o'clock positions. Install the differential housing cover.
    • Use the two bolts to position the differential housing cover on the differential housing.
  18. 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 11: Installing Differential Housing Cover Bolt
    G02760649Courtesy of FORD MOTOR CO.
  19. Fill the axle with the specified type and amount of lubricant. For additional information, refer to SPECIFICATIONS .
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