Differential Carrier - Dana 60: Removal

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.

Remove the front wheel hubs and the front axle shaft assemblies. For additional information, refer to WHEEL HUB .
Remove the differential housing cover and drain the lubricant.
- Position the differential housing to allow the lubricant to drain completely.
- Clean the gasket material from the differential housing and the differential housing cover.
  
  Fig 1: Removing Differential Housing Cover And Draining Lubricant
  Courtesy of FORD MOTOR CO.

CAUTION: Prior to removal, note the stamped mating letters positioning on the bearing caps and the differential housing for correct reassembly.

Fig 2: Removing Bearing Caps

Courtesy of FORD MOTOR CO.

Remove the bearing caps.

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.

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).
- Remove the dial indicator after spreading the differential housing.
  
  Fig 3: Spreading Differential Housing Using C-Clamp
  Courtesy of FORD MOTOR CO.

CAUTION: Do not damage the ring gear and pinion.

Using 2 pry bars, remove the differential with the bearing cups.
- Remove the C-clamp after removing the differential.
  
  Fig 4: Removing C-Clamp
  Courtesy of FORD MOTOR CO.