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Home >> Ford >> 2000 >> Excursion 5.4 L, RWD >> Repair and Diagnosis >> Drivelines & Axles >> Differentials & Drive Axles >> Differentials - DANA 50, 60, 80 & Ford 10.50" - Excursion & "F" Series Super Duty >> Overhaul >> Differential Assembly (DANA) >> Disassembly

Differential Assembly (DANA): Disassembly

  1. Remove the axle housing cover. Remove axle shafts. See HUB, BEARING & AXLE SHAFT  under REMOVAL & INSTALLATION.
    2. CAUTION: On Dana 50 and 60, DO NOT spread axle housing more than .015" (.38 mm). On Dana 80, maximum axle housing spread is .010" (.25 mm).
    Fig 1: Spreading Axle Housing (Dana Models)
    G95H28115Courtesy of FORD MOTOR CO.
  2. Note orientation of bearing cap identification letters. If side bearing caps are not identified, mark them for reassembly reference. Remove side bearing caps. Install Axle Housing Spreader (205-001) onto housing. See Fig 1. Mount dial indicator onto axle housing to measure amount of spread. Spread differential housing up to maximum specification.
  3. Remove dial indicator after housing has been spread. Carefully pry differential assembly out of housing. Remove housing spreader immediately to avoid housing distortion. Mark bearing races to identify from which side they were removed. Record size and position of side bearing shims between axle housing and side bearings outer races.
  4. Place Universal Bearing Remover (205-D064) into vise while removing differential side bearings. Keep bearings, bearing races and shims in sets, marked with bearing locations in axle housing. Place differential case into vise, with rags underneath to protect ring gear.
    5. NOTE: If anti-lock brake sensor ring is removed from axle housing, NEW sensor ring must be installed.
  5. Remove and discard ring gear bolts. Remove ring gear by tapping with soft-faced mallet. Remove pinion shaft. Rotate side gears until pinion gears align with case opening. Remove pinion gears and thrust washers.
  6. Remove side gears with thrust washers. Rotate nose of axle housing to horizontal position. Hold pinion flange with pinion flange holder. Remove pinion nut and washer. Using Flange Puller (205-D026), remove pinion flange. Using soft-face hammer, tap drive pinion out of housing.
    7. NOTE: Both oil slinger and baffle (if used) are part of shim pack and must be reused or replaced during reassembly procedure if originally equipped).
  7. Remove pinion seal with Bearing Race Puller (307-001) and slide hammer. Discard seal. Remove drive pinion outer bearing and oil slinger. Turn nose of axle housing downward.
  8. Remove pinion outer bearing race and inner bearing race using appropriate Bearing Race Driver (205-283) and Driver Handle (205-D055).
    9. NOTE: Pinion bearing adjusting shims and preload spacer (if equipped) may remain on pinion shaft, stick to bearing, or fall loose. Collect and save shims for reassembly.
  9. Remove shims and baffle (if used) from bearing race bore in axle housing. Using universal bearing remover, remove pinion inner bearing from drive pinion shaft.
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