Differential Carrier - 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.

Remove the front wheel hubs and the front axle shaft assemblies. Refer to HUB & WHEEL BEARINGS .
Remove the front axle assembly. Refer to AXLE ASSEMBLY .
- Place the axle assembly in a suitable repair stand.
Remove the differential housing cover and drain the lubricant.
- Position the differential housing to allow the lubricant to drain completely.
- Clean the gasket material from the differential housing and the differential housing cover.
  
  Fig 1: Draining Lubricant
  Courtesy of FORD MOTOR CO.

CAUTION: Prior to removal, note the stamped mating letters positioning on the bearing caps and the differential housing for correct reassembly.

Fig 2: Identifying Mating Letters Positioning On Bearing Caps And Differential Housing

Courtesy of FORD MOTOR CO.

Remove the bearing caps.

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

Using the special tools, spread the differential housing.
- Remove the dial indicator after spreading the differential housing.
  
  Fig 3: Spreading Differential Housing Using Special Tools
  Courtesy of FORD MOTOR CO.

CAUTION: Do not damage the ring gear and pinion.

Using 2 pry bars, remove the differential with the bearing cups.
- Remove the differential carrier spreader after removing the differential.
  
  Fig 4: Removing Differential With Bearing Cups Using 2 Pry Bars
  Courtesy of FORD MOTOR CO.