Differential Carrier - Dana 60: Installation

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.

NOTE: Do not spread the differential housing more than specified or damage to the housing may occur.

NOTE: Install the C-clamp at the 12 o'clock and 6 o'clock positions to allow the horizontal spread of the housing. Use a safety strap to restrain the C-clamp from rotation.

NOTE: Use a C-clamp with a minimum 15-in opening and a 16, 250 pound load limit.

Using a C-clamp, the Dial Indicator Gauge and the Clutch Housing Gauge, spread the differential housing 0.38 mm (0.015 in).
- Remove the Dial Indicator Gauge after spreading the differential housing.
  
  Fig 1: Seating Differential Into Differential Housing
  Courtesy of FORD MOTOR CO.
Using a soft-faced hammer, seat the differential into the differential housing.
- Remove the clamp after seating the differential in the differential housing.
NOTE: Match the positioning of the mating letters on the bearing caps and the differential housing.

Install the 2 bearing caps and the 4 bolts.
- Tighten to 108 Nm (80 lb-ft).
  
  Fig 2: Locating Mating Letters On Bearing Caps And Differential Housing
  Courtesy of FORD MOTOR CO.
Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, measure backlash at 3 equally spaced points.
- The backlash must be within the specifications 0.13-0.20 mm (0.005-0.008 in) and cannot vary more than 0.05 mm (0.002 in) between points checked.
  
  Fig 3: Measuring Backlash Using Dial Indicator Gauge With Holding Fixture
  Courtesy of FORD MOTOR CO.
NOTE: Clean the differential housing cover mounting surfaces with a suitable solvent to remove all traces of oil film or foreign material.

NOTE: The differential housing cover requires the use of silicone sealant material rather than a gasket.

NOTE: Install the differential housing cover within 15 minutes of applying the silicone material.

Apply the specified bead of silicone rubber sealer as shown below.

Fig 4: Applying Bead Of Silicone Rubber Sealer
Courtesy of FORD MOTOR CO.
NOTE: Allow one hour curing time before filling the axle with lubricant.

NOTE: Place 2 cover bolts into the differential housing cover at the 2 o'clock and 8 o'clock positions. This will help to position the differential housing cover onto the differential housing.

Install the remaining 8 differential housing cover bolts.
- Tighten to 61 Nm (45 lb-ft).
  
  Fig 5: Locating Differential Housing Cover Bolts
  Courtesy of FORD MOTOR CO.
Install the axle shafts and seals. For additional information, refer to AXLE SHAFT SEAL .
Fill the axle with the specified type and quantity of lubricant.
NOTE: Make sure that the nut retainer cap is correctly positioned to allow for cotter pin installation. Do not tighten or loosen the nut to align the retainer cap with the cotter pin hole. Overtightening of the fasteners may result in premature failure of steering linkage components.

Position the RH tie-rod and drag link. Install the tie-rod nut.
- Tighten to 115 Nm (85 lb-ft).
- Install the retainer cap and a new cotter pin.