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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 646 (Front Drive Axle/Differential -- Excursion & F250-F550 Super Duty) >> Removal And Installation >> Differential Bearings - Dana 60 >> Removal

Differential Bearings - Dana 60: Removal

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the differential carrier. Refer to DIFFERENTIAL CARRIER - DANA 60 .
  2. Remove and discard the nut and washer.
    • Use the special tool to prevent the flange from turning while removing the nut.
      Fig 1: Removing Flange Nut Using Special Tools
      G02769773Courtesy of FORD MOTOR CO.
  3. Using the special tool, remove the flange.
    Fig 2: Removing Flange Using Special Tools
    G02769774Courtesy of FORD MOTOR CO.
    4. CAUTION: Do not damage the pinion, the bearings or the cup.
  4. Remove the pinion.
    • Using a soft-face hammer, tap the pinion through the outer bearing. Remove the pinion through the rear of the differential housing.
      Fig 3: Removing Pinion
      G02769775Courtesy of FORD MOTOR CO.
  5. Using the special tools, remove the pinion seal. Discard the seal.
    Fig 4: Removing Pinion Seal Using Special Tools
    G02769776Courtesy of FORD MOTOR CO.
  6. Remove the oil slinger and the differential pinion bearing.
    Fig 5: Removing Oil Slinger And Differential Pinion Bearing
    G02769777Courtesy of FORD MOTOR CO.
  7. Using the special tools, remove the outer pinion bearing cup, the inner pinion bearing cup, and the oil baffle.
    • Use special tools 205-D055 and 205-D051 to remove the inner pinion bearing cup.
    • Use special tools 205-D055 and 205-D054 to remove the outer pinion bearing cup.
      Fig 6: Identifying Special Tool
      G02769778Courtesy of FORD MOTOR CO.
  8. Remove and discard the collapsible spacer.
    Fig 7: Removing Collapsible Spacer
    G02769779Courtesy of FORD MOTOR CO.
  9. Using the special tool, remove the differential pinion bearing.
    Fig 8: Removing Differential Pinion Bearing Using Special Tools
    G02769780Courtesy of FORD MOTOR CO.
    10. NOTE: Discard the drive pinion position shim if bent or nicked. Measure and record the shim thickness if discarding the shim.
  10. Remove the drive pinion position shim.
  11. Place the differential carrier into a vise with soft jaws.
  12. Using the special tool, remove the differential bearings.
    Fig 9: Removing Differential Bearings Using Special Tools
    G02769781Courtesy of FORD MOTOR CO.
  13. Remove the differential bearing shims.
    • Wire the shims together and mark from which side they were removed.
      Fig 10: Removing Differential Bearing Shims
      G02769782Courtesy of FORD MOTOR CO.
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