Differential Bearings - Dana 60: Removal

WARNING: This page is about a different car, the 2013 Ford F-550 Super Duty, 2013 Ford F-450 Super Duty, 2013 Ford F-350 Super Duty, and 2013 Ford F-250 Super Duty. 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 .
NOTE: Index-mark the driveshaft to the pinion flange to maintain correct driveline balance.

Remove and discard the 4 driveshaft flange bolts and 2 retainers. Position the driveshaft aside.

Fig 1: Locating Driveshaft Flange Bolts
Courtesy of FORD MOTOR CO.
Using the Drive Pinion Flange Holding Fixture to prevent the flange from turning, remove and discard the pinion nut and washer.

Fig 2: Locating Pinion Nut And Washer
Courtesy of FORD MOTOR CO.
Using the Drive Pinion Flange Remover, remove the pinion flange.

Fig 3: Locating Pinion Flange
Courtesy of FORD MOTOR CO.
NOTE: Do not damage the pinion, the bearings or the cup.

Using a soft-face hammer, tap the pinion through the outer bearing. Remove the pinion through the rear of the differential housing.

Fig 4: Removing Pinion Through Rear Of Differential Housing
Courtesy of FORD MOTOR CO.
Using the Slide Hammer and Bushing Remover, remove the pinion seal. Discard the seal.

Fig 5: Removing Pinion Seal Using Slide Hammer And Bushing Remover
Courtesy of FORD MOTOR CO.
Remove the oil slinger and the differential pinion bearing.

Fig 6: Locating Differential Pinion Bearing
Courtesy of FORD MOTOR CO.
Using a suitable tool, remove the outer pinion bearing cup, the inner pinion bearing cup and the oil baffle.
- Use the Handle and the Bearing Cup Remover/Installer (205-D051) to remove the inner pinion bearing cup.
- Use the Handle and the Bearing Cup Remover/Installer (205-D054) to remove the outer pinion bearing cup.
Remove and discard the collapsible spacer.

Fig 7: Locating Collapsible Spacer
Courtesy of FORD MOTOR CO.
Using the Drive Pinion/Differential Carrier Puller, remove the differential pinion bearing.

Fig 8: Removing Differential Pinion Bearing Using Drive Pinion/Differential Carrier Puller
Courtesy of FORD MOTOR CO.
NOTE: Discard the drive pinion position shim if bent or nicked. Measure and record the shim thickness if discarding the shim.

Remove the drive pinion position shim.
Place the differential carrier into a vise with soft jaws.
Using the Drive Pinion/Differential Carrier Puller, remove and discard the differential bearings.

Fig 9: Removing Differential Bearings Using Drive Pinion/Differential Carrier Puller
Courtesy of FORD MOTOR CO.
Remove the differential bearing shims.
- Wire the shims together and mark from which side they were removed.
  
  Fig 10: Locating Differential Bearing Shims
  Courtesy of FORD MOTOR CO.