Differential Carrier - Dana 60: Removal

All axles 

1. Remove 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.

Full-floating axle 

2. Remove the differential housing cover. For additional information, refer to Differential Housing Cover .

All axles 

NOTE: Note the positions of the mating letters stamped vertically and horizontally on the bearing caps and the differential housing before removing the bearing caps. Matching the letters is important at the time of installation.
3. To ease removal of the differential assembly, loosen the bolts, then pry the differential case, bearing cups and outboard spacers outward until they are loose in the differential housing.
Fig 1: Installing Bearing Caps & Bolts, Aligning Letters With Those On Differential Housing
Courtesy of FORD MOTOR CO.
4. Remove the 4 bolts and the 2 bearing caps.
NOTE: Do not spread the differential housing more than specified or damage to the housing may occur.
5. Using the Dial Indicator Gauge with Holding Fixture and Differential Carrier Spreader, spread the differential housing to the specification. Remove Dial Indicator after spreading the housing.
Fig 2: Spreading Differential Housing To Specification Using Differential Carrier Spreader & Dial Indicator Gauge With Holding Fixture
Courtesy of FORD MOTOR CO.
NOTE: It will be necessary to use large pry bars to remove the differential carrier from the differential housing. Do not damage the differential ring rear when carrying out this step.
NOTE: Mark or tag the differential bearing cups, indicating from which side they were removed.
6. Remove the differential assembly with the 2 bearing cups.
Fig 3: Removing Differential Assembly With Bearing Cups
Courtesy of FORD MOTOR CO.
NOTE: Mark or tag the outboard spacers indicating from which side they were removed.
7. Remove the outboard spacers.
Fig 4: Outboard Spacers
Courtesy of FORD MOTOR CO.