Differential Carrier - 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 axle shafts and seals. For additional information, refer to AXLE SHAFT SEAL .
Remove the cotter pin, retainer cap and the RH outer tie-rod end nut.
- Discard the cotter pin.
Using the C-Frame and Screw, disconnect the RH tie-rod and the drag link. Position the drag link aside.

Fig 1: Disconnecting RH Tie-Rod And Drag Link Using C-Frame And Screw
Courtesy of FORD MOTOR CO.
Remove the 10 bolts and the differential housing cover. Drain the lubricant.
- Clean the gasket material from the differential housing and the differential housing cover.
NOTE: Prior to removal, note the positioning of the stamped mating letters on the bearing caps and the differential housing for correct reassembly.

Remove the 4 bolts and the 2 bearing caps.

Fig 2: Locating Mating Letters Positioning On Bearing Caps And Differential Housing
Courtesy of FORD MOTOR CO.
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 with Holding Fixture 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 3: Seating Differential Into Differential Housing
  Courtesy of FORD MOTOR CO.
Using a pry bar, remove the differential with the bearing cups.
- Remove the C-clamp after removing the differential.