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Differential Bearings - Dana 70

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Special Tools

Illustration Tool Name Tool Number
GF0006599
 2-Jaw Puller 205-D026 (D80L-1002-L) or equivalent
GF0000827
 Alignment Adapter 205-D031 (D85T-4020-F46) or equivalent
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) or equivalent
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-D030 (D80T-4020-F45) or equivalent
GF0000827
 Gauge Disc 205-D037 (D81T-4020-F50) or equivalent
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)
GF0000831
 Installer, Drive Pinion Bearing Cone 205-005 (T53T-4621-C)
GF0006638
 Installer, Rear Axle Bearing/Oil Seal 205-092 (T75T-1165-DA)
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) or equivalent
GF0006306
 Set, Master Bearing 205-D047 (D81T-4222-DR) or equivalent
GF0006306
 Set, Master Bearing 205-D048 (D81T-4222-ER) or equivalent
GF0004054
 Slide Hammer 100-001 (T50T-100-A)
GF0003212
 Spreader, Differential Carrier 205-001 (TOOL-4000-E) or equivalent
GF0012186
 Step Plate 205-D012 (D80L-630-1) or equivalent
GF0000822
 Step Plate 205-D019 (D80L-630-8) or equivalent
Material

Item Specification
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 70
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 70 .
    2. NOTE: Mark or tag the outboard spacers indicating from which side they were removed.
  2. Remove the outboard spacers.
    • Inspect the spacers for nicks, bending and grooved conditions. Discard them if necessary.
    3. Fig 2: Outboard Spacers
    GF0006309Courtesy of FORD MOTOR CO.
  3. Using the Drive Pinion/Differential Carrier Puller, remove the differential bearings.
    • Place the left and right differential bearing shims with the respective outboard spacers.
    4. Fig 3: Removing Differential Bearings Using Drive Pinion/Differential Carrier Puller
    GF0044653Courtesy of FORD MOTOR CO.
  4. To maintain driveline balance, index-mark the driveshaft flange yoke and the pinion flange.
    5. Fig 4: Marking Driveshaft Flange & Pinion Flange
    GF0003040Courtesy of FORD MOTOR CO.
  5. Remove the 4 bolts.
    6. Fig 5: 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.
  6. Using a suitable tool as shown, disconnect the driveshaft flange yoke from the pinion flange and support the driveshaft using mechanic's wire.
    7. Fig 6: 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.
  7. Use the Drive Pinion Flange Holding Fixture to prevent the flange from turning while removing the lock nut and washer.
    8. Fig 7: Holding Pinion Flange With Special Tool
    G03883491Courtesy of FORD MOTOR CO.
  8. Index-mark the pinion flange and the drive pinion stem for correct alignment during installation.
    9. Fig 8: Placing Index Marks On Pinion Flange
    GF0000818Courtesy of FORD MOTOR CO.
  9. Using the 2-Jaw Puller, remove the pinion flange.
    10. Fig 9: Removing Pinion Flange Using Special Tools
    G03883519Courtesy of FORD MOTOR CO.
    NOTE: There are drive pinion bearing preload shims and a preload spacer 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 and spacer for reassembly.
  10. Using a soft-face hammer, tap the pinion out of the pinion bearing cup and remove it through the rear of the differential housing.
    11. Fig 10: Removing Pinion
    G03883493Courtesy of FORD MOTOR CO.
  11. Using the Bushing Remover and Slide Hammer, remove and discard the pinion seal.
    12. Fig 11: Removing Pinion Seal Using Special Tools
    G03883494Courtesy of FORD MOTOR CO.
  12. Remove the oil slinger and the pinion bearing.
  13. Remove the outer pinion bearing cup.
  14. Remove the inner pinion bearing cup.
  15. Using the Drive Pinion/Differential Carrier Puller, remove the inner pinion bearing.
    16. Fig 12: 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.
  16. Remove the drive pinion position shim.
  17. 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.
    18. Fig 13: Identifying Special Tool
    G03883498Courtesy of FORD MOTOR CO.
  18. Tighten the Drive Bearing Cup Installer to seat the pinion bearing cups into their bores.
    19. Fig 14: 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.
  19. Check that the cups have seated correctly in their bores.
    20. Fig 15: Checking Clearance Between Cup & Bore With Specification
    G03878664Courtesy of FORD MOTOR CO.
  20. Install the outboard spacers in the side from which they were removed.
    21. Fig 16: 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.
  21. Place the Master Bearing Set on the differential case hubs and position the assembly into the differential housing.
    • For Model 70TR axle, use tool 205-D048.
    • For Model 70 axle, use tool 205-D047.
    22. Fig 17: 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.
  22. 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.
    23. Fig 18: 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.
  23. Force the differential case as far as possible toward the indicator. With force still applied, set the indicator at 0.
  24. Force the differential case as far as it will go in the opposite direction. Record the total differential case end play reading.
  25. 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.
    26. NOTE: This step simulates pinion bearing preload.
  26. Install the Adapters, Gauge Disc and Bearings.
    • Using a N.m (lb-in) torque wrench, tighten the Adapter to specification.
    • Tighten to 2.26-5.09 Nm (20-45 lb-in).
    27. Fig 19: Exploded View Of Special Tool Components (Model 70TR)
    GF0012192Courtesy of FORD MOTOR CO.
    Fig 20: Exploded View Of Special Tool Components (Model 70)
    GF0012193Courtesy of FORD MOTOR CO.
    NOTE: Offset the Adapter as shown to obtain an accurate reading.
  27. Rotate the Adapter several half-turns to seat the pinion bearings and position the Adapter tool as shown.
    28. Fig 21: Rotating Special Tool
    G03883649Courtesy of FORD MOTOR CO.
  28. Install the Gauge Tube.
    1. Position the Gauge Tube.
      • For Model 70TR axles, use tool 205-D038.
      • For Model 70 axles, use tool 205-D033.
    2. Install the 2 bearing caps.
    3. Install the 4 bolts.
      • Tighten to 108 Nm (80 lb-ft).
    29. Fig 22: 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 devise.
    NOTE: Do not attempt to force the gauge or shim between the Adapter and Gauge Tube. A slight drag indicates a correct selection.
  29. Using a feeler gauge or flat, clean drive pinion position shims, measure between the special tools.
    30. Fig 23: Identifying Drive Pinion Bearing Adjustment Shim
    GF0003085Courtesy of FORD MOTOR CO.
  30. Notice the (+) or (-) etching on the pinion and adjust the new shim thickness to compensate for the difference.
    • For example, a pinion etched with m+8 (+3) requires 0.08 mm ( 0.0003 in) less shimming than a pinion etched "0". This means to increase the mounting distance by the amount etched in the pinion, subtract 0.08 mm (0.003 in) from the drive pinion position shim selected for installation. A pinion etched m-8 (-3), requires 0.08 mm (0.003 in) more shimming than a pinion etched "0". In this instance, add 0.08 mm (0.003 in) to the drive pinion position shim selected for installation to decrease the pinion mounting distance by the amount etched in the pinion.
    31. NOTE: Follow the drive pinion bearing preload shim and drive pinion position shim assembly sequence as directed or unit failure may result.
  31. Install the correct thickness drive pinion position shim on the pinion.
    32. NOTE: Always use the same new inner pinion bearing installed when taking the measurement for drive pinion shim selection.
  32. , install the pinion bearing.
    33. Fig 24: Installing Pinion Bearing Using Drive Pinion Bearing Cone Installer & Bearing/Oil Seal Plate & A Suitable Press
    GF0044671Courtesy 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. On Model 70 axles, add the thickness of the pinion preload spacer to the thickness of the old drive pinion bearing preload shims.
  33. 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
    34. NOTE: The pinion preload spacer must always go on the pinion before the drive pinion bearing preload shims.
  34. Assemble the pinion preload spacer onto the pinion.
  35. Assemble the drive pinion bearing preload shims onto the pinion and install the pinion into the differential housing.
  36. Install the outer pinion bearing.
  37. Install the pinion flange.
  38. 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 N.m (250 lb-ft).
    39. Fig 25: Holding Pinion Flange With Special Tool
    G03883491Courtesy of FORD MOTOR CO.
  39. Using a 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.
    40. Fig 26: Checking Drive Pinion Bearing Preload
    G03883517Courtesy of FORD MOTOR CO.
  40. With the drive pinion at the correct preload as determined earlier in this procedure, remove and discard the lock nut and the washer. Use the Drive Pinion Flange Holding Fixture to prevent the flange from turning.
    41. Fig 27: Holding Pinion Flange With Special Tool
    G03883491Courtesy of FORD MOTOR CO.
  41. Using the 2-Jaw Puller, remove the pinion flange.
    42. Fig 28: Removing Pinion Flange Using Special Tools
    G03883519Courtesy of FORD MOTOR CO.
  42. Lubricate the pinion seal rubber lips.
    • Use premium rear axle lubricant.
  43. Using a suitable driver, install the pinion seal.
    • After installation, verify that the garter spring did not pop out of the seal. If the garter spring popped out, install a new pinion seal.
  44. Coat the inside of the pinion flange with a small amount of rear axle lubricant.
  45. Install the pinion flange.
    • Align the index marks of the pinion flange and pinion stem.
  46. Use the Drive Pinion Flange Holding Fixture to prevent the flange from turning while installing the new washer and lock nut.
    • Tighten to 339 N.m (250 lb-ft).
    47. Fig 29: Holding Pinion Flange With Special Tool
    G03883491Courtesy of FORD MOTOR CO.
  47. Position the differential carrier assembly with the Master Bearings in the axle housing. Install the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge and locate the tip of the Clutch Housing Gauge on a flat surface.
    48. Fig 30: 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.
  48. Force the differential case away from the drive pinion. With force still applied, set the indicator at 0.
  49. Force the differential ring gear into mesh with the pinion to obtain an indicator reading. Record the reading.
  50. Remove the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge and the differential case from the differential housing.
    51. Fig 31: Placing Master Bearing Set On Differential Case Hubs & Positioning Assembly Into Differential Housing
    GF0044660Courtesy of FORD MOTOR CO.
  51. Remove the master bearings from the differential case.
  52. 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.
  53. Using the Differential Carrier Bearing Installer, install the differential bearing on the LH side of the differential case.
    54. Fig 32: Installing Differential Bearing On LH Side Of Differential Case Using Differential Carrier Bearing Installer
    GF0044665Courtesy of FORD MOTOR CO.
  54. 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.
  55. 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.
      • For Model 70TR axles, use tool 205-D012.
      • For Model 70 axles, use tool 205-D019.
    2. Using the Differential Carrier Bearing Installer, drive the differential bearing onto the hub.
    56. Fig 33: Installing Differential Bearing Using Differential Carrier Bearing Installer & Step Plate
    GF0044666Courtesy of FORD MOTOR CO.
  56. Assemble the differential bearing cups to the differential bearings.
    57. NOTE: Do not spread the differential housing more than specified or damage to the component may occur.
  57. Using the Dial Indicator Gauge with Holding Fixture 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 and Differential Carrier Spreader.
    58. Fig 34: 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.
  58. Install the bearing caps, aligning the letters with those on the differential housing.
    • Tighten to 108 Nm (80 lb-ft).
    59. Fig 35: Installing Bearing Caps & Bolts, Aligning Letters With Those On Differential Housing
    GF0044668Courtesy of FORD MOTOR CO.
  59. Confirm the total preload.
    • Using a 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.
    60. Fig 36: Checking Torque To Rotate Pinion
    G03883530Courtesy of FORD MOTOR CO.
  60. 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.
    61. Fig 37: Measuring Differential Ring Gear & Pinion Backlash Using Special Tools
    G03918386Courtesy of FORD MOTOR CO.
  61. 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.
  62. Install the axle shafts. For additional information, refer to WHEEL HUBS AND BEARINGS - FULL FLOATING AXLE - DANA article.
    63. 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.
  63. 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).
    64. Fig 38: Identifying Tighten Sequence Of Driveshaft Flange Bolts
    G03883532Courtesy of FORD MOTOR CO.
    NOTE: Install the differential housing cover within 15 minutes of applying the silicone, or it will be necessary to apply new sealant.
  64. Apply a continuous bead of silicone sealant, of the specified thickness, to the differential housing cover.
    65. Fig 39: Applying Sealant To Differential Housing Cover With Specification
    G03883533Courtesy of FORD MOTOR CO.
  65. Place 2 bolts into the differential housing cover at the 8 o'clock and 2 o'clock positions. Install the differential housing cover.
    • Use the 2 bolts to position the differential housing cover on the differential housing.
  66. Install the remaining bolts. Tighten the bolts alternately and evenly.
    • Tighten Grade 5 bolts to 47 N.m (35 lb-ft).
    • Tighten Grade 8 bolts to 61 N.m (45 lb-ft).
    • Allow one-hour cure time before filling the axle with the correct amount of specified lubricant.
    67. Fig 40: Identifying Differential Housing Cover Bolt
    G03883433Courtesy of FORD MOTOR CO.
  67. Fill the axle with the specified type and amount of lubricant. For additional information, refer to SPECIFICATIONS .
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