LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2000 >> Taurus LX, 3.0 2, AX4N >> Repair and Diagnosis >> External Pages >> Different car >> Section 1311 (Rear Drive Axle/Differential - DANA 60 And 70) >> In-Vehicle Servicing >> Differential Bearings - Dana 60

Differential Bearings - Dana 60

WARNING: This page is about a different car, the 2008 Ford RV Cutaway, 2008 Ford Econoline, 2008 Ford E450 Super Duty, and 2008 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
Special Tools

Illustration Tool Name Tool Number
GF0006599
 2-Jaw Puller 205-D026 (D80L-1002-L) or equivalent
GF0000827
 Alignment Adapter 205-105 (T76P-4020-A3)
GF0000829
 Adapter for 205-S127 205-111 (T76P-4020-A11)
GF0003131
 Adapter for 205-S156 205-159 (T80T-4020-F42)
GF0003078
 Adapter for 205-S156 205-160 (T80T-4020-F43)
GF0000024
 Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C)
GF0000025
 Dial Indicator Gauge with Holding Fixture 100-D002 (D78P-4201-B) or equivalent
GF0000771
 Gauge, Clutch Housing 308-021 (T75L-4201-A)
GF0006324
 Gauge, Disc 205-125 (T78P-4020-A15)
GF0000830
 Gauge Tube 205-D033 (D80T-4020-F48) or equivalent
GF0000830
 Gauge Tube 205-D038 (D81T-4020-F51) or equivalent
GF0006327
 Handle 205-D055 (D81L-4000-A) or equivalent
GF0000772
 Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A)
GF0003251
 Installer, Differential Carrier Bearing 205-D044 (D81T-4221-A) or equivalent
GF0003254
 Installer, Drive Pinion Bearing Cup 205-014 (T60K-4616-A)
GF0006638
 Installer, Rear Axle Bearing/Oil Seal (Model 60) 205-092 (T75T-1165-DA)
GF0006306
 Master Bearing Set 205-D047 (D81T-4222-DR) or equivalent
GF0006306
 Master Bearing Set 205-D048 (D81T-4222-ER) or equivalent
GF0000832
 Plate, Bearing/Oil Seal 205-090 (T75L-1165-B)
GF0006639
 Puller, Drive Pinion/Differential Carrier 205-D036 (D81L-4220-A) or equivalent
GF0006301
 Remover, Bushing 307-001 (TOOL-1175-AC)
GF0012185
 Remover/Installer, Bearing Cup 205-D051 (D81T-4628-A) or equivalent
GF0012185
 Remover/Installer, Bearing Cup 205-D054 (D81T-4628-D) or equivalent
GF0004054
 Slide Hammer 100-001 (T50T-100-A)
GF0003212
 Spreader, Differential Carrier 205-001 (TOOL-4000-E)
GF0012186
 Step Plate 205-D012 (D80L-630-1) or equivalent
Material

Item Specification
Additive Friction Modifier
XL-3 (US); CXL-3 (Canada)		 EST-M2C118-A
Motorcraft SAE 75W-140 Synthetic Rear Axle Lubricant
XY-75W140-QL (US); CXY-75W140-1L (Canada)		 WSL-M2C192-A
Motorcraft SAE 80W-90 Premium Rear Axle Lubricant
XY-80W90-QL (US); CXY-80W90-1L (Canada)		 WSP-M2C197-A
Threadlock and Sealer
TA-25		 WSK-M2G351-A5
Ultra Silicone Sealant
TA-29		 -
Fig 1: Exploded View Of Differential Bearings With Torque Specifications - Dana 60
GF0044669Courtesy of FORD MOTOR CO.
Item Part Number Description
1 - Bearing cap bolt (4 required) (part of 4010)
2 - Bearing cap (2 required) (part of 4010)
3 4204 Differential assembly
4 4221 Differential carrier bearing cones
5 4222 Differential carrier bearing cups
6 4K067 Outboard spacers
7 4209 Drive pinion
8 4663 Pinion preload shim
9 4630 Inner pinion bearing cone
10 4628 Inner pinion bearing cup
11 4663 Pinion preload shim
12 4616 Outer pinion bearing cup
13 4621 Outer pinion bearing cone
14 4676 Pinion oil seal
15 4851 Drive pinion flange
16 1124 Pinion nut washer
17 354845-5A Pinion nut
  1. Remove the differential carrier assembly. For additional information, refer to Differential Carrier - Dana 60 .
    2. NOTE: Wire tag the removed outboard spacers. Note from which side they were removed.
  2. Using the Drive Pinion Differential Carrier Puller, remove the differential bearings.
    • Place the left and right differential bearing shims with the respective outboard spacers.
    3. Fig 2: Removing Differential Bearings Using Drive Pinion/Differential Carrier Puller
    GF0044653Courtesy of FORD MOTOR CO.
  3. To maintain driveline balance, index-mark the driveshaft flange yoke and the pinion flange.
    4. Fig 3: Marking Driveshaft Flange & Pinion Flange
    GF0003040Courtesy of FORD MOTOR CO.
  4. Remove the 4 bolts.
    5. Fig 4: Driveshaft Flange Bolts
    GF0003041Courtesy of FORD MOTOR CO.
    NOTE: 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, with a suitable tool, to disconnect the yoke from the flange.
  5. Using a suitable tool as shown, disconnect the driveshaft flange yoke from the pinion flange and support the driveshaft using mechanic's wire.
    6. Fig 5: Disconnecting Driveshaft Flange Yoke From Pinion Flange
    G03878446Courtesy of FORD MOTOR CO.
    NOTE: Index-mark the pinion flange to the pinion shaft prior to removal.
  6. Use the Drive Pinion Flange Holding Fixture to prevent the flange from turning while removing the lock nut and washer.
    7. Fig 6: Holding Pinion Flange With Special Tool
    G03883491Courtesy of FORD MOTOR CO.
  7. Using the 2-Jaw Puller, remove the pinion flange.
    8. Fig 7: Removing Pinion Flange Using Special Tools
    G03883519Courtesy of FORD MOTOR CO.
    NOTE: There are drive pinion bearing preload shims on the spline-end of the pinion. These shims and spacer can stick to the pinion, the pinion bearing, or they can fall out of the differential housing. Collect and keep the shims for reassembly.
  8. Using a soft-face hammer, tap the pinion out of the pinion bearing cup and remove it through the rear of the differential housing.
    9. Fig 8: Removing Pinion
    G03883493Courtesy of FORD MOTOR CO.
  9. Using the Bushing Remover and Slide Hammer, remove and discard the pinion seal.
    10. Fig 9: Removing Pinion Seal Using Special Tools
    G03883494Courtesy of FORD MOTOR CO.
  10. Remove the oil slinger and the pinion bearing.
    11. NOTE: Do not nick the differential housing bore.
  11. Remove the outer pinion bearing cup.
  12. Remove the inner pinion bearing cup.
  13. Using the Drive Pinion/Differential Carrier Puller, remove the inner pinion bearing.
    14. Fig 10: Removing Inner Pinion Bearing Using Special Tool
    G03883497Courtesy of FORD MOTOR CO.
    NOTE: Discard the drive pinion position shim if bent or nicked. If discarding the shim, measure and record the shim thickness.
  14. Remove the drive pinion position shim.
  15. Position the inner and outer pinion bearing cups and the Drive Pinion Bearing Cup Installer in their respective differential housing bores.
    1. After placing the inner and outer pinion bearing cups in their bores, place the Drive Pinion Bearing Cup Installer (inner) on the inner pinion bearing cup.
    2. Place the Drive Pinion Bearing Cup Installer (outer) on the outer pinion bearing cup.
    3. Install the Drive Pinion Bearing Cup Installer.
    16. Fig 11: Identifying Special Tool
    G03883498Courtesy of FORD MOTOR CO.
  16. Tighten the Drive Pinion Bearing Cup Installer to seat the pinion bearing cups into their bores.
    17. Fig 12: Seating Pinion Bearing Cups Using Special Tool
    G03883499Courtesy of FORD MOTOR CO.
    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.
  17. Check that the cups have seated correctly in their bores.
    18. Fig 13: Checking Clearance Between Cup And Bore
    G03878664Courtesy of FORD MOTOR CO.
  18. Install the outboard spacers in the side from which they were removed.
    19. Fig 14: Outboard Spacers
    GF0006313Courtesy of FORD MOTOR CO.
    NOTE: Remove all nicks, burrs and dirt from the differential case hubs, to allow the bearings to rotate freely.
  19. Place the Master Bearing Set on the differential case hubs and position the assembly into the differential housing.
    • For semi-float axles, use tool 205-D047.
    20. Fig 15: Placing Master Bearing Set On Differential Case Hubs & Positioning Assembly Into Differential Housing
    GF0044660Courtesy of FORD MOTOR CO.
    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.
  20. Mount the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge as shown. Locate the tip of the Clutch Housing Gauge on a flat surface on one of the bolts.
    21. Fig 16: Mounting Dial Indicator Gauge With Holding Fixture
    GF0044661Courtesy of FORD MOTOR CO.
    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.
  21. Force the differential case as far as possible toward the indicator. With force still applied, set the indicator at 0.
  22. Force the differential case as far as it will go in the opposite direction. Record the total differential case end play reading.
  23. After making sure the reading is correct, remove the Dial Indicator Gauge and Clutch Housing Gauge and the differential from the differential housing. Do not remove the master bearings from the differential case at this time.
    24. Fig 17: Mounting Dial Indicator Gauge With Holding Fixture
    GF0044661Courtesy of FORD MOTOR CO.
    NOTE: 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.
  24. Assemble and position the following in the differential housing.
    1. Position the Adapter.
    2. Position the Alignment Adapter.
    3. Position the inner pinion bearing.
    4. Position the Gauge Disc.
    5. Position the Adapter.
    6. Position the outer pinion bearing.
    7. Thread on the Adapter.
    25. Fig 18: Identifying Pinion Bearings & Special Tools
    G03883577Courtesy of FORD MOTOR CO.
  25. Install the Gauge Tube.
    1. Position the Gauge Tube.
      • For semi-float axles, use tool 205-D033.
    2. Install the 2 bearing caps.
    3. Install the 4 bolts.
    4. Tighten to 108 Nm (80 lb-ft).
    26. Fig 19: Installing Gauge Tube Using Special Tool (205-D038)
    GF0044670Courtesy of FORD MOTOR CO.
    NOTE: Use a feeler gauge or flat, clean drive pinion position shims as a measuring device.
    NOTE: Do not attempt to force the gauge or shim between the Gauge Tube and Adapter. A slight drag indicates a correct selection.
  26. Using a feeler gauge or flat, clean drive pinion position shims, measure between the special tools. Record the measurement. Refer to Differential Ring And Pinion - Dana 60  for shim selection information.
    • Remove the Adapters after making the correct shim selection.
    27. Fig 20: Identifying Drive Pinion Bearing Adjustment Shim
    GF0000838Courtesy of FORD MOTOR CO.
    NOTE: Follow the drive pinion bearing preload shim and drive pinion position shim assembly sequence as directed or unit damage may result.
  27. Install the correct thickness drive pinion position shim on the pinion.
  28. 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 back face 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 illustrate the method to increase or decrease backlash and differential bearing preload.
    29. Fig 21: Pinion & Ring Gear Preloads
    GF0012191Courtesy of FORD MOTOR CO.
    NOTE: Always use the same new inner pinion bearing installed when taking the measurement for drive pinion shim selection.
  29. Using the Rear Axle Bearing/Oil Seal Installer and Bearing/Oil Seal Plate and a suitable press, install the pinion bearing.
    • For semi-float axles, use tool 205-092.
    30. Fig 22: Installing Differential Pinion Bearing Using Special Tools
    G03883514Courtesy of FORD MOTOR CO.
    NOTE: Use the thickness of the old drive pinion bearing preload shims as a starting point for setting pinion bearing preload.
  30. 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.
    AVAILABLE DRIVE PINION BEARING PRELOAD SHIMS

    mm Inch
    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
  31. Assemble the drive pinion bearing preload shims onto the pinion and install the pinion into the differential housing.
  32. Install the outer pinion bearing.
  33. Install the pinion flange.
  34. Use the Drive Pinion Flange Holding Fixture to prevent the flange from turning while installing the old washer and the lock nut.
    • Tighten to 339 Nm (250 lb-ft).
    35. Fig 23: Using Drive Pinion Flange Holding Fixture To Prevent Flange From Turning While Removing Lock Nut & Washer
    GF0044656Courtesy of FORD MOTOR CO.
  35. Using an Nm (lb-in) 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.
    36. Fig 24: Checking Drive Pinion Bearing Preload
    G03883517Courtesy of FORD MOTOR CO.
  36. Position the differential carrier assembly with the master bearings in the axle housing. Install the Dial Indicator Gauge and Clutch Housing Gauge and locate the tip of the Clutch Housing Gauge on a flat surface.
    37. Fig 25: Mounting Dial Indicator Gauge With Holding Fixture
    GF0044661Courtesy of FORD MOTOR CO.
    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.
  37. Force the differential case away from the drive pinion. With force still applied, set the indicator at 0.
  38. Force the differential ring gear into mesh with the pinion, to obtain an indicator reading. Record the reading.
  39. Remove the Dial Indicator Gauge and Clutch Housing Gauge and the differential case from the differential housing.
    40. Fig 26: Placing Master Bearing Set On Differential Case Hubs & Positioning Assembly Into Differential Housing
    GF0044660Courtesy of FORD MOTOR CO.
  40. Remove the master bearings from the differential case.
  41. 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.
  42. Using the Differential Carrier Bearing Installer, install the differential bearing on the LH side of the differential case.
    43. Fig 27: Installing Differential Bearing On LH Side Of Differential Case Using Differential Carrier Bearing Installer
    GF0044665Courtesy of FORD MOTOR CO.
  43. 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.
  44. Using the Differential Carrier Bearing Installer and Step Plate, install the differential bearing.
    1. Place the Step Plate on the differential bearing to protect it during the installation of the opposite bearing.
    2. Using the Differential Carrier Bearing Installer, drive the differential bearing onto the hub.
    45. Fig 28: Installing Differential Bearing Using Differential Carrier Bearing Installer & Step Plate
    GF0044666Courtesy of FORD MOTOR CO.
  45. Assemble the differential bearing cups to the differential bearings.
    46. NOTE: Do not spread the differential housing more than specified or damage to the component may occur.
  46. Using the Dial Indicator Gauge and Differential Carrier Spreader, spread the differential housing to the specification.
    • Use a rawhide hammer to seat the differential into the differential housing pocket.
      • Remove the Dial Indicator Gauge with Holding Fixture and Differential Carrier Spreader.
    47. Fig 29: Spreading Differential Housing To Specification Using Differential Carrier Spreader & Dial Indicator Gauge With Holding Fixture
    GF0044667Courtesy of FORD MOTOR CO.
    NOTE: Match the mating letters as noted during disassembly.
  47. Install the bearing caps and bolts, aligning the letters with those on the differential housing.
    • Tighten to 108 Nm (80 lb-ft).
    48. Fig 30: Installing Bearing Caps & Bolts, Aligning Letters With Those On Differential Housing
    GF0044668Courtesy of FORD MOTOR CO.
  48. Confirm the total preload.
    • Using an Nm (lb-in) 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.
    49. Fig 31: Checking Torque To Rotate Pinion
    G03883530Courtesy of FORD MOTOR CO.
  49. Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, measure the differential ring gear and pinion backlash at 3 equally spaced points.
    50. Fig 32: Measuring Differential Ring Gear & Pinion Backlash Using Special Tools
    G03918386Courtesy of FORD MOTOR CO.
  50. Carry out the tooth contact pattern check to verify the final pinion position is correct. For additional information, refer to DRIVELINE SYSTEM - GENERAL INFORMATION article.
  51. Install the axle shafts. For additional information, refer to Axle Shaft - Semi-Floating Axle .
    52. NOTE: 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.
  52. 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).
    53. Fig 33: Identifying Tighten Sequence Of Driveshaft Flange Bolts
    G03883532Courtesy of FORD MOTOR CO.
  53. Fill the axle with the specified type and amount of lubricant. For additional information, refer to SPECIFICATIONS .
scientia non olet · About LEMON Manuals