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Differential Bearings - Dana 60: Installation

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  1. Place the special tools on the differential case hubs, and position the assembly into the differential housing.
    • Use special tool 205-D047.
      Fig 1: Placing Special Tools On Differential Case Hubs
      G02769783Courtesy of FORD MOTOR CO.
    2. NOTE: Use a dial indicator with a minimum travel capacity of 5.08 mm (0.200 inch).
    NOTE: Repeat this step until there is a consistent reading.
  2. Determine the total thickness of the differential bearing shims to install on the differential case hubs, less the preload, which is calculated later in this procedure. Record this measurement as the total case end play.
    1. Position the special tool.
    2. Position the special tool.
      • Locate the tip of the tool on a flat surface of one of the ring gear bolt spot faces.
    3. Force the ring gear as far as possible toward the special tool.
    4. With the pressure still applied, zero the special tool.
    5. Force the ring gear as far as it will go in the opposite direction.
    6. Record the reading.
      Fig 2: Positioning Special Tool
      G02769784Courtesy of FORD MOTOR CO.
      Fig 3: Forcing Ring Gear
      G02769785Courtesy of FORD MOTOR CO.
  3. Remove the differential case with the special tool from the differential housing.
    • Do not remove the special tool from the differential case hubs.
      Fig 4: Removing Differential Case With Special Tool From Differential Housing
      G02769786Courtesy of FORD MOTOR CO.
  4. Install the inner oil baffle and the inner and outer pinion bearing cups.
    1. Position the oil baffle and the bearing cups in the differential housing.
    2. Place the special tools on the inner and outer bearing cups.
      • Place special tool 205-006 B1 on the outer pinion bearing cup.
      • Place special tool 205-006 B2 on the inner pinion bearing cup.
    3. Install and tighten special tool 205-098 to seat the cups.
      • Remove the special tools after seating the cups.
        Fig 5: Positioning Oil Baffle And Bearing Cups In Differential Housing
        G02769787Courtesy of FORD MOTOR CO.
        Fig 6: Installing Bearing Cup
        G02769788Courtesy of FORD MOTOR CO.
    5. 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 7: Identifying Feeler Gauge
    G02769789Courtesy of FORD MOTOR CO.
  5. Check that the cups have seated correctly in their bores.
    6. 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.
  6. Assemble and position the following in the differential housing.
    1. Position the adapter 205-160.
    2. Position the adapter 205-105.
    3. Position the inner pinion bearing.
    4. Position the adapter 205-125.
    5. Position the adapter 205-159.
    6. Position the outer pinion bearing.
    7. Thread on the adapter 205-111.
      Fig 8: Assembling And Positioning Differential Housing Components
      G02769790Courtesy of FORD MOTOR CO.
    7. NOTE: This step simulates pinion bearing preload.
    Fig 9: Identifying Special Tool Tightening Specification
    G02769791Courtesy of FORD MOTOR CO.
  7. Using a Nm (inch-pound) torque wrench, tighten the special tool to the specification.
    8. NOTE: Offset the special tool to obtain an accurate reading.
    Fig 10: Positioning Special Tool
    G02769792Courtesy of FORD MOTOR CO.
  8. Rotate the special tool several half-turns to seat the pinion bearings. Position the special tool as shown.
  9. Install the special tool.
    1. Position the special tool.
      • Use tool 205-D033.
    2. Install the bearing caps.
    3. Install the bolts.
      • Tighten to 108 Nm (80 lb-ft).
        Fig 11: Installing Special Tool
        G02769793Courtesy of FORD MOTOR CO.
    10. NOTE: Use a feeler gauge or flat, clean drive pinion position shims as a measuring device.
    NOTE: Do not attempt to force the gauge or shim between the special tools. A slight drag indicates a correct selection.
  10. Using a feeler gauge or flat, clean drive pinion position shims, measure the gap between the special tools. Record the measurement.
    • Remove the special tools after making the correct shim selection.
      Fig 12: Measuring Gap Between Special Tools
      G02769794Courtesy of FORD MOTOR CO.
  11. Notice the (+) or (-) etching on the pinion, and adjust the new shim thickness to compensate for the difference of these 2 figures.
    • For example, a pinion etched with m+8 (+3) requires 0.08 mm (0.003 inch) less shimming than a pinion etched "0". This means to increase the mounting distance by the amount etched in the pinion, subtract 0.08 mm (0.003 inch) from the drive pinion position shim selected for installation. A pinion etched m-8 (-3), requires 0.08 mm (0.003 inch) more shimming than a pinion etched "0". In this instance, add 0.08 mm (0.003 inch) to the drive pinion position shim selected for installation to decrease the pinion mounting distance by the amount etched in the pinion.
      Fig 13: Identifying Pinion Etched
      G02769795Courtesy of FORD MOTOR CO.
    12. CAUTION: Follow the drive pinion bearing preload shim and drive pinion position shim assembly sequence as directed or unit failure can result.
  12. Install the correct thickness drive pinion position shim on the pinion.
    • To change the pinion adjustment, drive pinion position shims are available in the thickness shown in the following chart. Measure each shim separately with a micrometer.
      1. Available 
      2. Drive 
      3. Pinion 
      4. Position 
      5. Shims 
        DRIVE PINION POSITION SHIMS THICKNESS SPECIFICATION

        mm inch
        1.22 0.048
        1.27 0.050
        1.32 0.052
        1.37 0.054
        1.42 0.056
        1.47 0.058
        1.52 0.060
        1.57 0.062
  13. Using the special tools, install the differential pinion bearing.
    Fig 14: Installing Differential Pinion Bearing Using Special Tools
    G02769796Courtesy of FORD MOTOR CO.
  14. Using a suitable driver, install the pinion seal.
    • Lightly coat the pinion seal lip with axle lubricant.
      Fig 15: Installing Pinion Seal
      G02769797Courtesy of FORD MOTOR CO.
  15. Install a new collapsible spacer.
    Fig 16: Installing New Collapsible Spacer
    G02769798Courtesy of FORD MOTOR CO.
    16. CAUTION: Do not damage the pinion, the bearings, the seal or the cup.
    Fig 17: Inserting Pinion Into Differential Housing
    G02769799Courtesy of FORD MOTOR CO.
  16. Insert the pinion into the differential housing and seat the inner bearing into the bearing cup.
    17. CAUTION: Never use a metal hammer on the pinion flange or install the flange with power tools. If necessary, use a plastic hammer to tap on a tight fitting flange while holding the backside of the drive pinion.
    Fig 18: Installing Flange
    G02769800Courtesy of FORD MOTOR CO.
  17. Lightly coat the flange splines and seal mating area with lubricant, then install the flange with a new washer and nut.
    18. CAUTION: Never back off the pinion nut to reduce preload. If preload reduction is necessary, install a new collapsible spacer and pinion nut.
  18. Tighten the nut.
    • Use the special tool to prevent the flange from turning while tightening the nut. Remove the special tool when taking pinion bearing torque preload readings.
    • Rotate the pinion occasionally to verify that the bearings are seating correctly.
      Fig 19: Tightening Flange Nut Using Special Tools
      G02769801Courtesy of FORD MOTOR CO.
  19. Take frequent pinion bearing torque preload readings.
    • Tighten to a rotational torque of 1.7-3.4 Nm (15-30 lb-in).
      Fig 20: Measuring Pinion Bearing Torque Preload
      G02769802Courtesy of FORD MOTOR CO.
  20. Position the differential case with the special tool into the differential housing.
    Fig 21: Positioning Differential Case With Special Tool Into Differential Housing
    G02769803Courtesy of FORD MOTOR CO.
    21. NOTE: Repeat this step until there is a consistent reading.
  21. Determine the total thickness of differential bearing shims to install under the differential bearing on the ring gear side of the differential case. Record this measurement, as the shim thickness required for the ring gear side of the differential case.
    1. Position the special tool.
    2. Position the special tool.
    3. Force the ring gear into mesh with the pinion.
      • Rock the ring gear to allow the teeth of the gears to mesh.
    4. With the pressure still applied, zero the special tool.
    5. Force the ring gear away from the pinion.
    6. Record the reading.
      Fig 22: Positioning Special Tool
      G02769804Courtesy of FORD MOTOR CO.
      Fig 23: Forcing Ring Gear
      G02769805Courtesy of FORD MOTOR CO.
  22. Remove the differential case with the special tool from the differential housing.
    • Remove the special tool from the differential case.
      Fig 24: Removing Differential Case With Special Tool From Differential Housing
      G02769806Courtesy of FORD MOTOR CO.
  23. Place the required thickness of differential bearing shims on the ring gear side of the differential case. Refer to the measurement recorded, as the shim thickness required for the ring gear side of the differential case. Differential bearing shims are available in the thickness shown in the following chart.
    • For example, a reading of 0.045 in (1.01 mm) requires that 1.14 mm (0.045 in) shims be placed on the ring gear side of the differential case.
      1. Available 
      2. Differential 
      3. Bearing 
      4. Shims 
        DIFFERENTIAL BEARING SHIMS THICKNESS SPECIFICATION

        mm inch
        0.076 0.003
        0.127 0.005
        0.254 0.010
        0.762 0.030
  24. Using the special tool(s), install the differential bearing.
    Fig 25: Installing Differential Bearing Using Special Tools
    G02769807Courtesy of FORD MOTOR CO.
  25. Determine the total thickness of differential bearing shims to install under the differential bearing on the drive pinion side of the differential case.
    • Subtract the measurement recorded, as the shim thickness required for the ring gear side of the differential case, from the total case end play measurement taken at the beginning of the assembly procedure. Then, add 0.38 mm (0.015 in) to the total. This is the total amount of differential bearing shims to install under the differential bearing on the drive pinion side of the differential case.
  26. Place the amount of differential bearing shims, as determined by the calculation made in the previous step, on the drive pinion side of the differential case.
  27. Using the special tools, install the differential bearing.
    1. Place the special tool under the bearing to protect it during the bearing installation.
    2. Using the special tool(s), install the bearing.
      Fig 26: Installing Differential Bearing Using Special Tools
      G02769808Courtesy of FORD MOTOR CO.
  28. Position the differential bearing cups on the bearings.
    Fig 27: Positioning Differential Bearing Cups On Bearings
    G02769809Courtesy of FORD MOTOR CO.
    29. CAUTION: Do not spread the differential housing more than specified.
    CAUTION: Do not damage the ring gear and pinion.
  29. Using the special tools, spread the differential housing.
    • Use a soft-face hammer to seat the differential into the differential housing.
      • Remove the special tools after seating the differential in the differential housing.
        Fig 28: Spreading Differential Housing Using Special Tools
        G02769810Courtesy of FORD MOTOR CO.
    30. CAUTION: Match the positioning of the mating letters on the bearing caps and the differential housing.
  30. Install the bearing caps.
    • Tighten to 108 Nm (80 lb-ft).
      Fig 29: Identifying Mating Letters On Bearing Caps And Differential Housing
      G02769811Courtesy of FORD MOTOR CO.
  31. Using the special tools, measure backlash at 3 equally spaced points.
    • The backlash must be within the specifications, and cannot vary more than 0.05 mm (0.002 in) between points checked.
      • Make the necessary corrections by moving shims from one side of the differential case to the other, until the correct backlash adjustment is achieved.
        • Correct for high backlash by moving the ring gear toward the pinion.
        • Correct for low backlash by moving the ring gear away from the pinion.
          Fig 30: Measuring Backlash Using Special Tools
          G02769812Courtesy of FORD MOTOR CO.
  32. Apply marking compound and rotate the differential assembly 5 complete revolutions.
  33. Verify an acceptable pattern check. Refer to DIAGNOSIS AND TESTING .
    34. CAUTION: Clean the differential housing cover mounting surfaces with a suitable solvent, to remove all traces of oil film or foreign material.
    NOTE: The differential housing cover requires the use of silicone sealant material rather than a gasket.
    NOTE: Install the differential housing cover within 15 minutes of applying the silicone material.
    Fig 31: Applying Specified Bead Of Silicone Rubber Sealer
    G02769813Courtesy of FORD MOTOR CO.
  34. Apply the specified bead of silicone rubber sealer as shown.
    35. CAUTION: Allow 1 hour curing time before filling the axle with lubricant.
    NOTE: Place 2 cover bolts into the differential housing cover at the 2 o'clock and 8 o'clock positions. This will help to position the differential housing cover onto the differential housing.
  35. Install the differential housing cover.
    • Tighten to 47 Nm (35 lb-ft).
      Fig 32: Installing Differential Housing Cover
      G02769814Courtesy of FORD MOTOR CO.
  36. Install the axle assembly. Refer to AXLE ASSEMBLY .
  37. Install the axle shaft assemblies and the front wheel hubs. Refer to HUB & WHEEL BEARINGS .
  38. Fill the axle with the specified type and quantity of lubricant.
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