Differential Carrier - Dana 60: Installation

WARNING: This page is about a different car, the 2005 Ford Pickup, 2005 Ford F550 Super Duty, 2005 Ford F450 Super Duty, and 2005 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: Install the C-clamp at the 12 and 6 o'clock positions to allow the horizontal spread of the housing.

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

CAUTION: Do not damage the ring gear and pinion.

NOTE: Use a C-clamp with a minimum 15 inch opening and a 16,250 lb. load limit.

Using a C-clamp, spread the differential housing 0.38 mm (0.015 in).
- Use a soft-face hammer to seat the differential into the differential housing.
  - Remove the clamp after seating the differential in the differential housing.
    
    Fig 1: Spreading Differential Housing Using C-Clamp
    Courtesy of FORD MOTOR CO.

CAUTION: Match the positioning of the mating letters on the bearing caps and the differential housing.

Install the bearing caps.
- Tighten to 108 Nm (80 lb-ft).
  
  Fig 2: Installing Bearing Caps
  Courtesy of FORD MOTOR CO.
Using the special tools, measure backlash at 3 equally spaced points.
- The backlash must be within the specifications 0.13-0.20 mm (0.005-0.008 in) and cannot vary more than 0.05 mm (0.002 in) between points checked.
  
  Fig 3: Measuring Differential Ring Gear Backlash
  Courtesy of FORD MOTOR CO.

CAUTION: Clean the differential housing cover mounting surfaces with a suitable solvent to remove all traces of oil film or foreign material.

NOTE: The differential housing cover requires the use of silicone sealant material rather than a gasket.

NOTE: Install the differential housing cover within 15 minutes of applying the silicone material.

Fig 4: Applying Silicone Rubber Sealer To Differential Housing Cover

Courtesy of FORD MOTOR CO.

Apply the specified bead of silicone rubber sealer as shown.

CAUTION: Allow one hour curing time before filling the axle with lubricant.

NOTE: Place 2 cover bolts into the differential housing cover at the 2 o'clock and 8 o'clock positions. This will help to position the differential housing cover onto the differential housing.

Install the differential housing cover.
- Tighten to 47 Nm (35 lb-ft).
  
  Fig 5: Identifying Differential Housing Cover Bolt
  Courtesy of FORD MOTOR CO.
Install the axle shaft assemblies and the front wheel hubs. For additional information, refer to WHEEL HUB .
Fill the axle with the specified type and quantity of lubricant.