Differential Ring And Pinion - Dana 60: Removal

WARNING: This page is about a different car, the 2007 Ford Pickup, 2007 Ford F550 Super Duty, 2007 Ford F450 Super Duty, and 2007 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Remove the differential carrier. For additional information, refer to Differential Carrier - Dana 60 .

Fig 1: Driveshaft Flange Bolt

Courtesy of FORD MOTOR CO.

NOTE: Index-mark the driveshaft to the pinion flange to maintain correct driveline balance.

Remove and discard the 4 driveshaft flange bolts. Position the driveshaft aside.

Fig 2: Holding Pinion Flange With Special Tool

Courtesy of FORD MOTOR CO.

Using the special tool to prevent the flange from turning, remove and discard the pinion nut and washer.

Fig 3: Marking Flange And Pinion Shaft

Courtesy of FORD MOTOR CO.

Using the special tool, remove the pinion flange.

Fig 4: Removing Pinion

Courtesy of FORD MOTOR CO.

Using a soft-faced hammer, tap the pinion through the outer bearing. Remove the pinion through the rear of the differential housing.
- Discard the pinion, bearing and collapsible spacer.

Fig 5: Removing Pinion Seal Using Special Tools

Courtesy of FORD MOTOR CO.

Using the special tools, remove the pinion seal. Discard the seal.

Fig 6: Differential Pinion Bearing

Courtesy of FORD MOTOR CO.

Remove the oil slinger and the differential pinion bearing.
Using a suitable tool, remove the outer pinion bearing cup, the inner pinion bearing cup and the oil baffle.
- Use 205-D055 and 205-D051 to remove the inner pinion bearing cup.
- Use 205-D055 and 205-D054 to remove the outer pinion bearing cup.
Place the differential carrier into a vise with soft jaws.

Fig 7: Removing Differential Bearings Using Special Tool

Courtesy of FORD MOTOR CO.

Using the special tool, remove the differential bearings.

Fig 8: Differential Bearing Shim

Courtesy of FORD MOTOR CO.

Remove the differential bearing shims.
- Wire the shims together and mark from which side they were removed.

Fig 9: Tapping Ring Gear Bolts

Courtesy of FORD MOTOR CO.

CAUTION: Place shop towels under the ring gear to prevent ring gear damage.

NOTE: Discard the bolts after removing them from the differential case.

Remove the ring gear.
- Remove and discard 8 of the 12 ring gear bolts. Leave 4 loosely assembled bolts spaced equally apart from each other.
- Tap each of the 4 bolt heads alternately with a soft face hammer to loosen the ring gear. Remove the 4 bolts and the ring gear. Discard the bolts.