Differential Carrier - Dana 60: Installation

All axles 

1. Assemble the differential bearing cups to the differential bearings.
NOTE: Do not spread the differential housing more than specified or damage to the housing may occur.
2. Using the Dial Indicator Gauge with Holding Fixture and Differential Housing Spreader, spread the differential housing to the specification.
   • Use a rawhide hammer to seat the differential and outboard spacers into the differential housing pocket.
     • Remove the Dial Indicator and Differential Housing Spreader.
Fig 1: Spreading Differential Housing To Specification Using Differential Carrier Spreader & Dial Indicator Gauge With Holding Fixture
Courtesy of FORD MOTOR CO.
NOTE: Match the mating letters as noted during removal.
3. Install the 2 bearing caps and the 4 bearing cap bolts, aligning the letters with those on the differential housing.
   • Tighten to 108 Nm (80 lb-ft).
Fig 2: Installing Bearing Caps & Bolts, Aligning Letters With Those On Differential Housing
Courtesy of FORD MOTOR CO.
4. Using the Dial Indicator Gauge and Clutch Housing Gauge, measure the differential ring gear and pinion backlash at 3 equally spaced points.
Fig 3: Measuring Differential Ring Gear & Pinion Backlash Using Special Tools
Courtesy of FORD MOTOR CO.

Full-floating axle 

5. Install the differential housing cover. For additional information, refer to Differential Housing Cover .

All axles 

6. Install the axle shafts. For additional information, refer to Axle Shaft - Semi-Floating Axle  or Axle Shaft - Full Floating Axle in WHEEL HUBS AND BEARINGS - FULL FLOATING AXLE - DANA article.