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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 775 (Rear Drive Axle/Differential - DANA 60 And 70) >> In-Vehicle Repair >> Differential Ring An Pinion - Dana 60 >> Removal & Installation

Removal & Installation

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the differential carrier assembly. For additional information, refer to DIFFERENTIAL CARRIER - DANA 60 .
    2. CAUTION: Mark or tag the outboard spacers indicating from which side they were removed.
  2. Remove the outboard spacers.
    • Inspect the spacers for nicks, bending and grooved conditions. Discard them if necessary.
      Fig 1: Identifying Outboard Spacers
      G03883483Courtesy of FORD MOTOR CO.
  3. Using the special tools, remove the differential bearings.
    • Place the left and right differential bearing shims with the respective outboard spacers.
      Fig 2: Removing Differential Bearings
      G03883484Courtesy of FORD MOTOR CO.
    4. NOTE: Use a vise with brass jaws or wood blocks.
  4. Place the differential case in a vise.
    5. NOTE: Whenever removing the ring gear bolts, always install new bolts upon assembly. Use grade 9 bolts for service replacement for all Dana rear axles.
    Fig 3: Identifying Ring Gear
    G03883485Courtesy of FORD MOTOR CO.
  5. Remove the bolts on the ring gear. Leave 4 bolts loosely assembly, 90 degrees apart.
  6. Tap each bolt head alternately with a rawhide or plastic hammer to loosen the ring gear. Remove the bolts and the ring gear.
    Fig 4: Removing Bolts And Ring Gear
    G03883486Courtesy of FORD MOTOR CO.
  7. If required, remove the anti-lock speed sensor ring with a soft-faced hammer. Discard the anti-lock speed sensor ring.
    Fig 5: Removing Anti-Lock Speed Sensor Ring
    G03883487Courtesy of FORD MOTOR CO.
  8. To maintain driveline balance, index-mark the driveshaft flange yoke and the pinion flange.
    Fig 6: Identifying Index-Marking On Driveshaft Flange Yoke And Pinion Flange
    G03883300Courtesy of FORD MOTOR CO.
  9. Remove the 4 bolts.
    Fig 7: Identifying Driveshaft Flange and Rear Axle Pinion Flange Bolts And Alignment Marks
    G03883559Courtesy of FORD MOTOR CO.
    10. CAUTION: The driveshaft flange yoke fits tightly on the pinion flange yoke. Never hammer on the driveshaft or any of its components to disconnect the yoke from the flange. Pry only in the area shown in Fig 8 with a suitable tool, to disconnect the yoke from the flange.
    Fig 8: Disconnecting Driveshaft Flange Yoke From Pinion Flange
    G03878446Courtesy of FORD MOTOR CO.
  10. Using a suitable tool as shown in Fig 8 disconnect the driveshaft flange yoke from the pinion flange and support the driveshaft using mechanic's wire.
    11. CAUTION: Index-mark the pinion flange to the pinion shaft prior to removal.
    Fig 9: Holding Pinion Flange With Special Tool
    G03883491Courtesy of FORD MOTOR CO.
  11. Use the special tool to prevent the flange from turning while removing the lock nut and washer.
  12. Using the special tool, remove the pinion flange.
    Fig 10: Removing Pinion Flange
    G03883519Courtesy of FORD MOTOR CO.
    13. NOTE: There are drive pinion bearing preload shims on the spline-end of the pinion. These shims and can stick to the pinion, the pinion bearing, or they can fall out of the differential housing. Collect and keep the shims for reassembly.
    Fig 11: Removing Pinion Out Of Pinion Bearing Cup
    G03883493Courtesy of FORD MOTOR CO.
  13. Using a soft-face hammer, tap the pinion out of the pinion bearing cup and remove it through the rear of the differential housing.
  14. Using the special tools, remove and discard the pinion seal.
    Fig 12: Removing Drive Pinion Seal
    G03883494Courtesy of FORD MOTOR CO.
  15. Remove the oil slinger and the pinion bearing.
    16. CAUTION: Do not nick the differential housing bore.
  16. Using the special tools, remove the outer pinion bearing cup.
    • For semi-float axles, use tools 205-D054 and 205-D055.
      Fig 13: Removing Outer Pinion Bearing Cup
      G03883495Courtesy of FORD MOTOR CO.
  17. Using the special tools, remove the inner pinion bearing cup.
    • For semi-float axles, use tools 205-D051 and 205-D055.
      Fig 14: Removing Inner Pinion Bearing Cup
      G03883496Courtesy of FORD MOTOR CO.
  18. Using the special tool, remove the inner pinion bearing.
    Fig 15: Removing Inner Pinion Bearing
    G03883497Courtesy of FORD MOTOR CO.
    19. NOTE: Discard the drive pinion position shim if bent or nicked. If discarding the shim, measure and record the shim thickness.
  19. Remove the drive pinion position shim.
  20. Position the inner and outer pinion bearing cups and the special tools in their respective differential housing bores.
    1. After placing the inner and outer pinion bearing cups in their bores, place the special tool (inner) on the inner pinion bearing cup.
    2. Place the special tool (outer) on the outer pinion bearing cup.
    3. Install the special tool.
      Fig 16: Installing Special Tool
      G03883498Courtesy of FORD MOTOR CO.
  21. Tighten the special tool to seat the pinion bearing cups into their bores.
    Fig 17: Seating Pinion Bearing Cups
    G03883499Courtesy of FORD MOTOR CO.
    22. 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 18: Checking Clearance Between Cup And Bore
    G03878664Courtesy of FORD MOTOR CO.
  22. Check that the cups have seated correctly in their bores.
    23. NOTE: The tab on the anti-lock speed sensor ring must be aligned with the slot in the differential case.
  23. Install the anti-lock speed sensor ring if removed.
    • Align the tab in the anti-lock speed sensor ring with the slot in the differential case. Start the 2 ring gear bolts through the differential case flange into the ring gear to make sure the differential case and the ring gear bolt hole align.
      Fig 19: Installing Anti-Lock Speed Sensor Ring
      G03883501Courtesy of FORD MOTOR CO.
  24. Press the anti-lock speed sensor ring on the differential case. The differential case flange acts as a pilot for the anti-lock speed sensor ring.
    Fig 20: Pressing Anti-Lock Speed Sensor Onto Differential Case
    G03883502Courtesy of FORD MOTOR CO.
  25. Apply threadlock to the new ring gear bolts.
  26. Install and tighten the grade 9 ring gear bolts alternately and evenly.
    • Tighten to 176 Nm (130 lb-ft).
      Fig 21: Identifying Ring Gear Bolts
      G03883503Courtesy of FORD MOTOR CO.
  27. Install the outboard spacers in the side from which they were removed.
    Fig 22: Identifying Outboard Spacers
    G03883404Courtesy of FORD MOTOR CO.
    28. NOTE: Remove all nicks, burrs and dirt from the differential case hubs, to allow the bearings to rotate freely.
  28. Place the special tool on the differential case hubs and position the assembly into the differential housing.
    • For semi-float axles, use tool 205-D047.
      Fig 23: Placing Special Tool On Differential Case Hubs
      G03883410Courtesy of FORD MOTOR CO.
    29. NOTE: Use a dial indicator with a minimum travel capability of 5.08 mm (0.200 in).
    NOTE: The rear axle uses a combination of differential bearing shims and selective outboard spacers to control differential case end play. The old outboard spacers provide a good starting point when setting end play. However, if additional shimming is necessary, beyond what the hardened differential bearing shims can provide, select and install different thickness outboard spacers.
    Fig 24: View Of Mounted Special Tool
    G03883506Courtesy of FORD MOTOR CO.
  29. Mount the special tools as shown in Fig 24. Locate the tip of special tool 308-021 on a flat surface on one of the bolts.
    30. NOTE: Repeat this step and the following step until the same reading appears on the indicator each time. Record the reading. This is the total differential bearing shim thickness required, less preload. The final calculation occurs later during assembly.
    Fig 25: Forcing Differential Case Away From Drive Pinion
    G03883523Courtesy of FORD MOTOR CO.
  30. Force the differential case as far as possible toward the indicator. With force still applied, set the indicator at 0.
  31. Force the differential case as far as it will go in the opposite direction. Record the total differential case end play reading.
    Fig 26: Forcing Differential Ring Gear Into Mesh With Pinion
    G03883524Courtesy of FORD MOTOR CO.
  32. After making sure the reading is correct, remove the special tools and the differential from the differential housing. Do not remove the master bearings from the differential case at this time.
    Fig 27: Mounting Dial Indicator
    G03883506Courtesy of FORD MOTOR CO.
    33. 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.
  33. Assemble and position the following in the differential housing.
    1. Position the special tool.
    2. Position the special tool.
    3. Position the inner pinion bearing.
    4. Position the special tool.
    5. Position the special tool.
    6. Position the outer pinion bearing.
    7. Thread on the special tool.
      Fig 28: Assembling Pinion Bearings Using Special Tools
      G03883577Courtesy of FORD MOTOR CO.
    34. NOTE: This step simulates pinion bearing preload.
    Fig 29: Assembling Inner And Outer Pinion Bearing Using Special Tools
    G03883511Courtesy of FORD MOTOR CO.
  34. Using a Nm (inch-pound) torque wrench, tighten the special tool to specification.
  35. Install the special tool.
    1. Position the special tool.
      • For semi-float axles, use tool 205-D033.
    2. Install the bearing caps.
    3. Install the bolts.
      • Tighten to 108 Nm (80 lb-ft).
        Fig 30: Installing Bearing Caps
        G03883512Courtesy of FORD MOTOR CO.
    36. NOTE: Use a feeler gauge or flat, clean drive pinion position shims as a measuring devise.
    NOTE: Do not attempt to force the gauge or shim between the special tools. A slight drag indicates a correct selection.
  36. Using a feeler gauge or flat, clean drive pinion position shims, measure between the special tools. Record the measurement. Refer to PINION RING GEAR VARIATION NUMBER  for shim selection information.
    • Remove the special tools after making the correct shim selection.
      Fig 31: Identifying Drive Pinion Bearing Adjustment Shim
      G03878604Courtesy of FORD MOTOR CO.
    37. CAUTION: Follow the drive pinion bearing preload shim and drive pinion position shim assembly sequence as directed or unit failure can result.
  37. Install the correct thickness drive pinion position shim on the pinion.
    38. NOTE: Always use the same new inner pinion bearing installed when taking the measurement for drive pinion shim selection.
    Fig 32: Installing Pinion Bearing
    G03883514Courtesy of FORD MOTOR CO.
  38. Using the special tool and a suitable press, install the pinion bearing.
    39. NOTE: Use the thickness of the old drive pinion bearing preload shims as a starting point for setting pinion bearing preload.
  39. Inspect the drive pinion bearing preload shims for damage. Discard them if necessary. New shims are available in the thickness shown in the following chart. See AVAILABLE DRIVE PINION BEARING PRELOAD SHIMS .
    AVAILABLE DRIVE PINION BEARING PRELOAD SHIMS

    mm inches
    0.36 0.014
    0.38 0.015
    0.41 0.016
    0.46 0.018
    0.51 0.020
    0.53 0.021
    0.56 0.022
    0.58 0.023
    0.76 0.030
  40. If the pinion bearing preload is within specification and the pinion position shim has changed, change the drive pinion bearing preload shims by the same amount.
    • The direction arrow pointing toward the pinion flange indicates that by removing the drive pinion position shim, the distance from the centerline of the tubes to the pinion backface increases, giving a plus (+) reading. The drive pinion bearing preload shim pack does not affect the pinion depth setting. However, if the pinion position is changed, the pinion preload will change and may require adjustment to bring the torque-to-rotate within specification. Arrows on the ring gear Fig 33 illustrate the method to increase or decrease backlash and differential bearing preload.
      Fig 33: Adjusting Backlash And Differential Bearing Preload
      G03883515Courtesy of FORD MOTOR CO.
  41. Assemble the drive pinion bearing preload shims onto the pinion and install the pinion into the differential housing.
  42. Install the outer pinion bearing.
  43. Install the pinion flange.
  44. Use the special tool to prevent the flange from turning while installing the old washer and the locknut.
    • Tighten to 339 Nm (250 lb-ft).
      Fig 34: Holding Pinion Flange With Special Tool
      G03883491Courtesy of FORD MOTOR CO.
  45. Using an inch-pound torque wrench, rotate the pinion. The torque must read as specified.
    • To increase the preload, remove drive pinion bearing preload shims. To decrease the preload, add shims.
      Fig 35: Checking Drive Pinion Bearing Preload
      G03883517Courtesy of FORD MOTOR CO.
  46. With the drive pinion at the correct preload as determined earlier in this procedure, remove and discard the locknut and the washer. Use the special tool to prevent the flange from turning.
    Fig 36: Holding Pinion Flange With Special Tool
    G03883491Courtesy of FORD MOTOR CO.
  47. Using the special tool, remove the pinion flange.
    Fig 37: Removing Pinion Flange
    G03883519Courtesy of FORD MOTOR CO.
  48. Lubricate the pinion seal rubber lips.
    • Use rear axle lubricant.
  49. Using a suitable driver, install the pinion seal.
    • After installation, verify that the garter spring did not pop out of the seal. If the garter spring popped out, install a new pinion seal.
      Fig 38: Installing Pinion Seal
      G04609857Courtesy of FORD MOTOR CO.
  50. Coat the inside of the pinion flange with a small amount of lubricant.
    • For semi-float axles, use rear axle lubricant.
  51. Install the pinion flange.
    52. CAUTION: Always install a new washer and locknut.
  52. Use the special tool to prevent the flange from turning while installing the new washer and locknut.
    • Tighten to 339 Nm (250 lb-ft).
      Fig 39: Holding Pinion Flange With Special Tool
      G03883491Courtesy of FORD MOTOR CO.
  53. Position the differential carrier assembly with the master bearings in the axle housing. Install the special tools and locate the tip of special tool 308-021 on a flat surface.
    Fig 40: Mounting Dial Indicator
    G03883506Courtesy of FORD MOTOR CO.
    54. NOTE: Repeat this step and the following step until the same reading appears on the indicator each time. This is the differential bearing shim thickness necessary between the differential case and the differential bearing on the differential ring gear side of the differential case.
    Fig 41: Forcing Differential Case Away From Drive Pinion
    G03883523Courtesy of FORD MOTOR CO.
  54. Force the differential case away from the drive pinion. With force still applied, set the indicator at 0.
  55. Force the differential ring gear into mesh with the pinion, to obtain an indicator reading. Record the reading.
    Fig 42: Forcing Differential Ring Gear Into Mesh With Pinion
    G03883524Courtesy of FORD MOTOR CO.
  56. Remove the special tools and the differential case from the differential housing.
    Fig 43: Removing Special Tools And Differential Case From Differential Housing
    G03883410Courtesy of FORD MOTOR CO.
  57. Remove the master bearings from the differential case.
  58. Place one shim, of the necessary thickness, as determined from the previous measurement, on the LH side of the differential case. If additional shimming is necessary, beyond what the hardened differential bearing shim can provide, select and install a different thickness outboard spacer.
  59. Using the special tool, install the differential bearing on the LH side of the differential case.
    Fig 44: Installing Differential Bearing On Differential Case
    G03883526Courtesy of FORD MOTOR CO.
  60. Determine the correct shim thickness and place it on the differential case hub on the RH side.
    • To determine the correct shim thickness, first, subtract the reading of the previous measurement from the total differential case end play reading. Then, add 0.25 mm (0.010 in) to this amount. This is the correct thickness shim to place on the hub. If additional shimming is necessary, beyond what the hardened differential bearing shim can provide, select and install a different thickness outboard spacer.
  61. Using the special tools, install the differential bearing.
    1. Place the special tool on the differential bearing to protect it during the installation of the opposite bearing.
    2. Using the special tool, drive the differential bearing onto the hub.
      Fig 45: Installing Differential Bearing
      G03883589Courtesy of FORD MOTOR CO.
  62. Assemble the differential bearing cups to the differential bearings.
    63. 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.
  63. 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.
        Fig 46: Spreading Differential Housing Using Special Tools
        G04414223Courtesy of FORD MOTOR CO.
    64. CAUTION: Match the mating letters as noted during disassembly.
  64. Install the bearing caps and bolts, aligning the letters with those on the differential housing.
    • Tighten to 108 Nm (80 lb-ft).
      Fig 47: Locating Differential Bearing Caps
      G04414224Courtesy of FORD MOTOR CO.
  65. Confirm the total preload.
    • Using an inch-pound torque wrench, check the torque to rotate the pinion. The reading must be higher than the initial reading (taken without the differential case installed) with new bearings installed as recommended by the following:
      • 3.54 and 3.73 = 0.9 Nm (8 lb-in)
      • 4.10 and 4.56 = 0.8 Nm (7 lb-in)
      • 4.63 and 5.13 = 0.8 Nm (7 lb-in)
    • If the total preload is too high, remove an equal amount of differential bearing shims from each differential case hub. If the total preload is too low, add an equal amount of differential bearing shims to each differential case hub.
      Fig 48: Adjusting Total Preload
      G03883530Courtesy of FORD MOTOR CO.
  66. Using the special tools, measure the differential ring gear and pinion backlash at three equally spaced points.
    Fig 49: Measuring Differential Ring Gear And Pinion Backlash
    G03918386Courtesy of FORD MOTOR CO.
  67. Carry out the tooth contact pattern check to verify the final pinion position is correct. For additional information, refer to CHECKING TOOTH CONTACT PATTERN AND CONDITION OF THE RING AND PINION .
  68. Install the axle shafts. For additional information, refer to AXLE SHAFT - SEMI-FLOATING AXLE .
    69. CAUTION: The driveshaft flange yoke fits tightly on the pinion flange pilot. To make sure that the yoke seats squarely on the flange, tighten the bolts evenly in a cross pattern as shown in Fig 50.
    CAUTION: Install the driveshaft with new bolts. If new bolts are not available, apply sealer to the threads of the original bolts.
  69. Position the driveshaft flange yoke on the pinion flange with the index marks aligned and install the new bolts.
    • Tighten to 112 Nm (83 lb-ft).
      Fig 50: Identifying Tightening Sequence Of Driveshaft Flange Yoke Bolts
      G03883532Courtesy of FORD MOTOR CO.
    70. 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 51: Applying Sealant To Differential Housing Cover
    G03883533Courtesy of FORD MOTOR CO.
  70. Apply a continuous bead of silicone sealant, of the specified thickness, to the differential housing cover.
  71. Place 2 bolts into the differential housing cover at the 8 o'clock and 2 o'clock positions. Install the differential housing cover.
    • Use the 2 bolts to position the differential housing cover on the differential housing.
  72. 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 a one-hour cure time before filling the axle with the correct amount of specified lubricant.
      Fig 52: Identifying Differential Housing Cover Bolt
      G03883433Courtesy of FORD MOTOR CO.
  73. Fill the axle with the specified type and amount of lubricant. For additional information, refer to SPECIFICATIONS .
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