Differential Ring And Pinion - 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: Removing Pinion Flange Using Drive Pinion Flange Remover
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 4: Removing Bearing And Collapsible Spacer
  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.
Place the differential carrier into a vise with soft jaws.
Using the Drive Pinion/Differential Carrier Puller, remove the differential bearings.

Fig 7: Identifying 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 8: Locating Differential Bearing Shims
  Courtesy of FORD MOTOR CO.
NOTE: 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.
  
  Fig 9: Tapping Bolts Of Differential Ring Gear
  Courtesy of FORD MOTOR CO.