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 Ring And Pinion - Dana 60

Differential Ring And Pinion - 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 (for use on model 60 axles)
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 Ring & Pinion With Torque Specifications - Dana 60
GF0044652Courtesy of FORD MOTOR CO.
Item Part Number Description
1 - Differential bearing cap bolt (4 required) (part of 4010)
2 - Differential bearing cap (2 required) (part of 4010)
3 4204 Ring gear bolts
4 4221 Differential carrier bearing cones
5 4222 Differential carrier bearing cups
6 4K067 Differential carrier bearing spacers
7 4209 Drive pinion
8 4663 Inner pinion position shim
9 4630 Inner pinion bearing cone
10 4628 Inner pinion bearing cup
11 4663 Outer pinion position shim
12 4616 Outer pinion bearing cup
13 4621 Outer pinion bearing cone
14 4676 Drive pinion oil seal
15 4851 Drive pinion flange
16 1124 Drive pinion washer
17 354845-5A Drive pinion nut
18 4204 Differential assembly
  1. Remove the differential carrier assembly. For additional information, refer to Differential Carrier - Dana 60 .
    2. NOTE: Mark or tag the outboard spacers indicating from which side they were removed.
  2. Remove the 2 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 2 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.
    NOTE: Use a vise with brass jaws or wood blocks.
  4. Place the differential case in a vise.
    5. NOTE: Whenever removing the ring gear bolts, always install new bolts upon assembly. Use Grade 9 bolts for service replacement for all Dana rear axles.
  5. Remove and discard 8 of the bolts on the ring gear. Leave 4 bolts loosely assembled, 90 degrees apart.
    6. Fig 4: Identifying Bolts On Ring Gear
    GF0044654Courtesy of FORD MOTOR CO.
  6. Tap each bolt head alternately with a rawhide or plastic hammer to loosen the ring gear. Remove and discard the 4 bolts and the ring gear.
    7. Fig 5: Tapping Each Bolt Head Alternately With A Rawhide Or Plastic Hammer To Loosen Ring Gear
    GF0044655Courtesy of FORD MOTOR CO.
  7. To maintain driveline balance, index-mark the driveshaft flange yoke and the pinion flange.
    8. Fig 6: Marking Driveshaft Flange & Pinion Flange
    GF0003040Courtesy of FORD MOTOR CO.
  8. Remove the 4 bolts.
    9. Fig 7: 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.
  9. Using a suitable tool as shown, disconnect the driveshaft flange yoke from the pinion flange and support the driveshaft using mechanic's wire.
    10. Fig 8: 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.
  10. Use the Drive Pinion Flange Holding Fixture to prevent the flange from turning while removing the lock nut and washer.
    11. Fig 9: Using Drive Pinion Flange Holding Fixture To Prevent Flange From Turning While Removing Lock Nut & Washer
    GF0044656Courtesy of FORD MOTOR CO.
  11. Using the 2-Jaw Puller, remove the pinion flange.
    12. Fig 10: 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 can stick to the pinion, the pinion bearing, or they can fall out of the differential housing. Collect and keep the shims for reassembly.
  12. Using a soft-face hammer, tap the pinion out of the pinion bearing cup and remove it through the rear of the differential housing.
    13. Fig 11: Removing Pinion
    G03883493Courtesy of FORD MOTOR CO.
  13. Using the Bushing Remover and Slide Hammer, remove and discard the pinion seal.
    14. Fig 12: Removing Pinion Seal Using Special Tools
    G03883494Courtesy of FORD MOTOR CO.
  14. Remove the oil slinger and the pinion bearing.
    15. NOTE: Do not nick the differential housing bore.
  15. Remove the outer pinion bearing cup.
  16. Remove the inner pinion bearing cup.
  17. Using the Drive Pinion/Differential Carrier Puller, remove the inner pinion bearing.
    18. Fig 13: 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.
  18. Remove the drive pinion position shim.
  19. 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.
    20. Fig 14: Identifying Special Tool
    G03883498Courtesy of FORD MOTOR CO.
  20. Tighten the Drive Pinion Bearing Cup Installer to seat the pinion bearing cups into their bores.
    21. Fig 15: 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.
  21. Check that the cups have seated correctly in their bores.
    22. Fig 16: Checking Clearance Between Cup & Bore With Specification
    G03878664Courtesy of FORD MOTOR CO.
  22. Start the 2 ring gear bolts through the differential case flange into the ring gear to make sure the differential case and the ring gear bolt hole align.
    23. Fig 17: Locating Ring Gear Bolts On Differential Case Flange
    GF0044657Courtesy of FORD MOTOR CO.
  23. Press the ring gear on the differential case. The differential case flange acts as a pilot for the ring gear.
    24. Fig 18: Pressing Ring Gear On Differential Case
    GF0044658Courtesy of FORD MOTOR CO.
  24. Apply threadlock to the 12 new ring gear bolts.
  25. Install and tighten the Grade 9 ring gear bolts alternately and evenly.
    • Tighten to 176 Nm (130 lb-ft).
    26. Fig 19: Locating Ring Gear Bolts
    GF0044659Courtesy of FORD MOTOR CO.
  26. Install the 2 outboard spacers in the side from which they were removed.
    27. Fig 20: Outboard Spacers
    GF0006313Courtesy of FORD MOTOR CO.
  27. 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.
    28. Fig 21: 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.
  28. Mount the Dial Indicator Gauge with Holding Fixture as shown. Locate the tip of Clutch Housing Gauge on a flat surface on one of the bolts.
    29. Fig 22: 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.
  29. Force the differential case as far as possible toward the indicator. With force still applied, set the indicator at 0.
    30. Fig 23: Forcing Differential Case As Far As Possible Toward Indicator
    GF0044662Courtesy of FORD MOTOR CO.
  30. Force the differential case as far as it will go in the opposite direction. Record the total differential case end play reading.
    31. Fig 24: Forcing Differential Case As Far As It Will Go In Opposite Direction
    GF0044663Courtesy of FORD MOTOR CO.
  31. After making sure the reading is correct, remove the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge and the differential from the differential housing. Do not remove the master bearings from the differential case at this time.
    32. Fig 25: Mounting Dial Indicator Gauge With Holding Fixture
    GF0044661Courtesy of FORD MOTOR CO.
    NOTE: Apply only a light oil film on the pinion bearings before assembling the tools.
  32. 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.
    33. Fig 26: Identifying Pinion Bearings & Special Tools
    G03883577Courtesy of FORD MOTOR CO.
    NOTE: This step simulates pinion bearing preload.
  33. Using a N.m (lb-in) torque wrench, tighten the Adapter Handle to specification.
    • Tighten to 2.26-5.09 Nm (20-45 lb-in).
    34. NOTE: Offset the Adapter as shown to obtain an accurate reading.
  34. Rotate the Adapter several half-turns to seat the pinion bearings and position the Adapter as shown.
    35. Fig 27: Rotating Special Tool
    G03883649Courtesy of FORD MOTOR CO.
  35. 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).
    36. NOTE: Using 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.
  36. Using a feeler gauge or flat, clean drive pinion position shims, measure between the Adapter and Gauge Tube. Record the measurement.
    • Remove the Adapter and Gauge Tube after making the correct shim selection.
    37. Fig 28: Identifying Drive Pinion Bearing Adjustment Shim
    GF0000838Courtesy of FORD MOTOR CO.
  37. Notice the (+) or (-) etching on the pinion and adjust the new shim thickness to compensate for preferred running depth.
    • For example, a pinion etched with m+8 (+3) requires 0.08 mm ( 0.003 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.
    38. NOTE: Follow the drive pinion bearing preload shim and drive pinion position shim assembly sequence as directed or unit damage can result.
  38. Install the correct thickness drive pinion position shim on the pinion.
    39. NOTE: Always use the same new inner pinion bearing installed when taking the measurement for drive pinion shim selection.
  39. Using the Bearing/Oil Seal Plate and Rear Axle Bearing/Oil Seal Installer and a suitable press, install the pinion bearing.
    40. Fig 29: 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.
  40. 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
  41. 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.
    42. Fig 30: Pinion & Ring Gear Preloads
    GF0012191Courtesy of FORD MOTOR CO.
  42. Assemble the drive pinion bearing preload shims onto the pinion and install the pinion into the differential housing.
  43. Install the outer pinion bearing.
  44. Install the pinion flange.
  45. 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).
    46. Fig 31: Using Drive Pinion Flange Holding Fixture To Prevent Flange From Turning While Removing Lock Nut & Washer
    GF0044656Courtesy of FORD MOTOR CO.
  46. 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.
    47. Fig 32: Checking Drive Pinion Bearing Preload
    G03883517Courtesy of FORD MOTOR CO.
  47. 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.
    48. Fig 33: Using Drive Pinion Flange Holding Fixture To Prevent Flange From Turning While Removing Lock Nut & Washer
    GF0044656Courtesy of FORD MOTOR CO.
  48. Using the 2-Jaw Puller, remove the pinion flange.
    49. Fig 34: Removing Pinion Flange Using Special Tools
    G03883519Courtesy of FORD MOTOR CO.
  49. Use rear axle lubricant to lubricate the pinion seal rubber lips.
  50. 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.
  51. Coat the inside of the pinion flange with a small amount of lubricant.
  52. Install the pinion flange.
    53. NOTE: Always install a new washer and lock nut.
  53. 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).
    54. Fig 35: Using Drive Pinion Flange Holding Fixture To Prevent Flange From Turning While Removing Lock Nut & Washer
    GF0044656Courtesy of FORD MOTOR CO.
  54. 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.
    55. Fig 36: 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.
  55. Force the differential case away from the drive pinion. With force still applied, set the indicator at 0.
    56. Fig 37: Forcing Differential Case As Far As Possible Toward Indicator
    GF0044662Courtesy of FORD MOTOR CO.
  56. Force the differential ring gear into mesh with the pinion, to obtain an indicator reading. Record the reading.
    57. Fig 38: Forcing Differential Case As Far As It Will Go In Opposite Direction
    GF0044663Courtesy of FORD MOTOR CO.
  57. Remove the Dial Indicator Gauge and Clutch Housing Gauge and the differential case from the differential housing.
    58. Fig 39: Locating Dial Indicator Gauge & Clutch Housing Gauge
    GF0044664Courtesy of FORD MOTOR CO.
  58. Remove the master bearings from the differential case.
  59. 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.
  60. Using the Differential Carrier Bearing Installer, install the differential bearing on the LH side of the differential case.
    61. Fig 40: Installing Differential Bearing On LH Side Of Differential Case Using Differential Carrier Bearing Installer
    GF0044665Courtesy of FORD MOTOR CO.
  61. 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.
  62. 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.
    63. Fig 41: Installing Differential Bearing Using Differential Carrier Bearing Installer & Step Plate
    GF0044666Courtesy of FORD MOTOR CO.
  63. Position the differential bearing cups on the differential bearings.
    64. NOTE: Do not spread the differential housing more than specified or damage to the component may occur.
  64. Using the Differential Carrier Spreader and Dial Indicator Gauge with Holding Fixture, spread the differential housing to the specification. Remove the Dial Indicator.
    • Use a rawhide hammer to seat the differential into the differential housing pocket.
      • Remove the Differential Carrier Spreader.
    65. Fig 42: 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.
  65. Install the 2 bearing caps and 4 bolts, aligning the letters with those on the differential housing.
    • Tighten to 108 Nm (80 lb-ft).
    66. Fig 43: Installing Bearing Caps & Bolts, Aligning Letters With Those On Differential Housing
    GF0044668Courtesy of FORD MOTOR CO.
  66. 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.
    67. Fig 44: Checking Torque To Rotate Pinion
    G03883530Courtesy of FORD MOTOR CO.
  67. 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.
    68. Fig 45: Measuring Differential Ring Gear & Pinion Backlash Using Special Tools
    G03918386Courtesy of FORD MOTOR CO.
  68. Carry out the tooth contact pattern check to verify the final pinion position is correct.
  69. Install the axle shafts. For additional information, refer to Axle Shaft - Semi-Floating Axle .
    70. 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.
  70. Position the driveshaft flange yoke on the pinion flange with the index marks aligned and install the 4 new bolts.
    • Tighten to 112 Nm (83 lb-ft).
    71. Fig 46: Identifying Tighten Sequence Of Driveshaft Flange Bolts
    G03883532Courtesy of FORD MOTOR CO.
  71. Fill the axle with the specified type and amount of lubricant. For additional information, refer to SPECIFICATIONS .
scientia non olet · About LEMON Manuals