Differential Ring And Pinion - Dana 60: Removal

WARNING: This page is about a different car, the 2005 Ford Pickup, 2005 Ford F550 Super Duty, 2005 Ford F450 Super Duty, and 2005 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 .
Remove and discard the nut and washer.
- Use the special tool to prevent the flange from turning while removing the nut.
  
  Fig 1: Removing Flange Nut And Washer
  Courtesy of FORD MOTOR CO.
Using the special tool, remove the flange.

Fig 2: Removing Flange
Courtesy of FORD MOTOR CO.

CAUTION: Do not damage the pinion, the bearings or the cup.

Remove the pinion.
- Using a soft-face hammer, tap the pinion through the outer bearing. Remove the pinion through the rear of the differential housing.
  
  Fig 3: Removing Pinion
  Courtesy of FORD MOTOR CO.
Using the special tools, remove the pinion seal. Discard the seal.

Fig 4: Removing Drive Pinion Seal
Courtesy of FORD MOTOR CO.
Remove the oil slinger and the differential pinion bearing.

Fig 5: Removing Oil Slinger And Differential Pinion Bearing
Courtesy of FORD MOTOR CO.
Using the special tools, remove the outer pinion bearing cup, the inner pinion bearing cup and the oil baffle.
- Use special tool 205-D055 and 205-D051 to remove the inner pinion bearing cup.
- Use special tool 205-D055 and 205-D054 to remove the outer pinion bearing cup.
  
  Fig 6: Removing Inner Pinion Bearing Cup
  Courtesy of FORD MOTOR CO.
Remove and discard the collapsible spacer.

Fig 7: Removing Collapsible Spacer
Courtesy of FORD MOTOR CO.
Place the differential carrier into a vise with soft jaws.
Using the special tool, remove the differential bearings.

Fig 8: Removing Differential Bearings
Courtesy of FORD MOTOR CO.
Remove the differential bearing shims.
- Wire the shims together and mark from which side they were removed.
  
  Fig 9: Removing Differential Bearing Shims
  Courtesy of FORD MOTOR CO.
Remove the ring gear.
1. Place the differential into a vise with soft jaws.
2. Remove and discard all but 4 of the bolts. Leave the 4 loosely assembled bolts spaced apart from each other.
3. Tap each bolt head alternately with a soft-face hammer to loosen the ring gear. Remove the bolts and the ring gear.
  - Discard the bolts.
    
    Fig 10: Removing Ring Gear
    Courtesy of FORD MOTOR CO.