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Differential Carrier - Dana 60: Removal

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  1. Remove the axle shafts. For additional information, refer to AXLE SHAFT - SEMI-FLOATING AXLE .
    2. CAUTION: Note the positions of the mating letters stamped vertically and horizontally on the bearing caps and the differential housing before removing the bearing caps. Matching the letters is important at the time of installation.
    Fig 1: Installing Bearing Caps
    G04414224Courtesy of FORD MOTOR CO.
  2. To ease removal of the differential assembly, loosen the bolts, then pry the differential case, bearing cups and outboard spacers outward until they are loose in the differential housing.
  3. Remove the bolts and the bearing caps.
    4. CAUTION: Do not spread the differential housing more than specified.
    Fig 2: Spreading Differential Housing
    G04414223Courtesy of FORD MOTOR CO.
  4. Using the special tools, spread the differential housing to the specification. Remove special tool 100-D002 after spreading the housing.
    5. CAUTION: It will be necessary to use large pry bars to remove the differential carrier from the differential housing. Do not damage the differential ring rear when carrying out this step.
    CAUTION: Mark or tag the differential bearing cups, indicating from which side they were removed.
    Fig 3: Removing Differential Assembly With Bearing Cups
    G03883758Courtesy of FORD MOTOR CO.
  5. Remove the differential assembly with the bearing cups.
    6. CAUTION: Mark or tag the outboard spacers indicating from which side they were removed.
    Fig 4: Identifying Outboard Spacers
    G03883483Courtesy of FORD MOTOR CO.
  6. Remove the outboard spacers.
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