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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 Ring and Pinion - Dana 60 >> Removal

Differential Ring and Pinion - 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
      G02769684Courtesy of FORD MOTOR CO.
  3. Using the special tool, remove the flange.
    Fig 2: Removing Flange Using Special Tools
    G02769685Courtesy 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
      G02769686Courtesy of FORD MOTOR CO.
  5. Using the special tools, remove the pinion seal. Discard the seal.
    Fig 4: Removing Pinion Seal Using Special Tools
    G02769687Courtesy of FORD MOTOR CO.
  6. Remove the oil slinger and the differential pinion bearing.
    Fig 5: Removing Oil Slinger
    G02769688Courtesy 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 tool 205-D055 and 205-D051 to remove the inner pinion bearing cup.
    • Use special tool 205-D055 and 205-D054 to remove the outer pinion bearing cup.
      Fig 6: Identifying Special Tools
      G02769689Courtesy of FORD MOTOR CO.
  8. Remove and discard the collapsible spacer.
    Fig 7: Removing Collapsible Spacer
    G02769690Courtesy of FORD MOTOR CO.
  9. Place the differential carrier into a vise with soft jaws.
  10. Using the special tool, remove the differential bearings.
    Fig 8: Removing Differential Bearings Using Special Tools
    G02769691Courtesy of FORD MOTOR CO.
  11. Remove the differential bearing shims.
    • Wire the shims together and mark from which side they were removed.
      Fig 9: Removing Differential Bearing Shims
      G02769692Courtesy of FORD MOTOR CO.
  12. Remove the ring gear.
    1. Place the differential into a vise with soft jaws.
    2. Remove and discard all but 4 of the bolts. Leave the 4 loosely assembled bolts spaced apart from each other.
    3. Tap each bolt head alternately with a soft-face hammer to loosen the ring gear. Remove the bolts and the ring gear.
      • Discard the bolts.
        Fig 10: Removing Ring Gear
        G02769693Courtesy of FORD MOTOR CO.
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