Differential Ring And Pinion - Dana 60: Installation

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Start 2 new bolts through the differential case flange and into the differential ring gear to make sure the differential ring gear and the differential case align.

Fig 1: Locating Differential Ring Gear Bolts
Courtesy of FORD MOTOR CO.
Install the remaining 10 new ring gear bolts and draw up the new ring gear bolts alternately and evenly.
- Tighten to 215 Nm (158 lb-ft).
  
  Fig 2: Identifying Ring Gear With Bolts
  Courtesy of FORD MOTOR CO.
Place the Dummy Bearing Set on the differential case hubs and position the assembly into the differential housing.

Fig 3: Placing Dummy Bearing Set On Differential Case Hubs
Courtesy of FORD MOTOR CO.
NOTE: Repeat this step until there is a consistent reading.

Force the differential case as far as possible toward the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge. With force applied, set the Dial Indicator Gauge at 0. Force the differential case as far as it will go in the opposite direction. Record the total differential case end play reading.

Fig 4: Measuring Differential Case End Play Reading (View 1 Of 2)
Courtesy of FORD MOTOR CO.

Fig 5: Measuring Differential Case End Play Reading (View 2 Of 2)
Courtesy of FORD MOTOR CO.
Remove the differential case with the Dummy Bearing Set from the differential housing.
- Do not remove the Dummy Bearing Set from the differential case hubs.
  
  Fig 6: Placing Dummy Bearing Set On Differential Case Hubs
  Courtesy of FORD MOTOR CO.
NOTE: Make sure the inner oil baffle is squarely under the inner pinion bearing cup.

Install the inner oil baffle and the inner and outer pinion bearing cups.
Using the Rear Axle Drawbar and Drive Pinion Bearing Cup Installer, install the pinion bearing cups.
- Place the following on the inner and outer bearing cups.
  - Place Installer 205-006-B1 on the outer pinion bearing cup.
  - Place Installer 205-006-B2 on the inner pinion bearing cup.
- Install and tighten the Rear Axle Drawbar to seat the cups.
  
  Fig 7: Identifying Rear Axle Drawbar
  Courtesy of FORD MOTOR CO.
NOTE: If the feeler gauge can fit between a cup and the bottom of its bore at any point around the cup, remove and reseat the cup.

Check that the cups have seated correctly in their bores.

Fig 8: Checking Clearance Between Cup And Bore
Courtesy of FORD MOTOR CO.
NOTE: If any of the gauge surfaces have nicks in them, remove the high spots with a medium India oilstone to prevent erroneous readings.

NOTE: Apply only a light oil film on the pinion bearings before assembling the tools.

Assemble and position the following in the differential housing in the following sequence:
1. Position the Adapter 205-160.
2. Position the Adapter 205-105.
3. Position the inner pinion bearing.
4. Position the Adapter 205-125.
5. Position the Adapter 205-159.
6. Position the outer pinion bearing.
7. Thread on the Adapter 205-111.
  
  Fig 9: Assembling Pinion Bearings Using Special Tools
  Courtesy of FORD MOTOR CO.
NOTE: This step simulates pinion bearing preload.

Using a Nm (lb-in) torque wrench, tighten the Adapter to set the rotational torque.
- Tighten to a rotational torque of 2.2 Nm (20 lb-in).
  
  Fig 10: Tightening Adapter Using Torque Wrench
  Courtesy of FORD MOTOR CO.
NOTE: Offset the Adapter to obtain an accurate reading.

Rotate the Adapter several half-turns to seat the pinion bearings. Position the Adapter as shown below.

Fig 11: Identifying Adapter Position
Courtesy of FORD MOTOR CO.
Install the Gauge Tube.
1. Install the 2 bearing caps.
2. Install the 4 bolts.
  - Tighten to 108 Nm (80 lb-ft).
    
    Fig 12: Installing Gauge Tube
    Courtesy of FORD MOTOR CO.
NOTE: Use a feeler gauge or flat, clean drive pinion position shims as a measuring device.

NOTE: Do not attempt to force the gauge or shim between the Adapter and Gauge Tube. A slight drag indicates a correct selection.

Using a feeler gauge or flat, clean drive pinion position shims, measure the gap between the Adapter and Gauge Tube. Record the measurement.

Fig 13: Measuring Gap Between Adapter And Gauge Tube Using Shims And Feeler Gauge
Courtesy of FORD MOTOR CO.
Notice the (+) or (-) etching on the pinion, and adjust the new shim thickness to compensate for the difference of these 2 figures.
- For example, a pinion etched with m+8 (+3) requires 0.08 mm (0.003 in) less shimming than a pinion etched "0". This means to increase the mounting distance by the amount etched in the pinion, subtract 0.08 mm (0.003 in) from the drive pinion position shim selected for installation. A pinion etched m-8 (-3), requires 0.08 mm (0.003 in) more shimming than a pinion etched "0". In this instance, add 0.08 mm (0.003 in) to the drive pinion position shim selected for installation to decrease the pinion mounting distance by the amount etched in the pinion.
  
  Fig 14: Identifying Etched Numbers Of Differential Ring Gear And Pinion
  Courtesy of FORD MOTOR CO.

NOTE: Follow the drive pinion bearing preload shim and drive pinion position shim assembly sequence as directed or unit failure can result.

Install the correct thickness drive pinion position shim on the pinion.

To change the pinion adjustment, drive pinion position shims are available in the thickness shown in the following chart. Measure each shim separately with a micrometer.

AVAILABLE DRIVE PINION POSITION SHIMS

mm	Inch
1.22	0.048
1.27	0.050
1.32	0.052
1.37	0.054
1.42	0.056
1.47	0.058
1.52	0.060
1.57	0.062

Using the Bearing Oil Seal Plate and Rear Axle Bearing/Oil Seal Installer, install the differential pinion bearing.

Fig 15: Installing Differential Pinion Bearing
Courtesy of FORD MOTOR CO.
Using a suitable driver, install the pinion seal.
- Lightly coat the pinion seal lip with lubricant.
  
  Fig 16: Installing Pinion Seal
  Courtesy of FORD MOTOR CO.
Install a new collapsible spacer.

Fig 17: Locating Collapsible Spacer
Courtesy of FORD MOTOR CO.
NOTE: Do not damage the pinion, the bearings, the seal or the cup.

Insert the pinion into the differential housing, and seat the inner bearing into the bearing cup.

Fig 18: Locating Pinion On Differential Housing
Courtesy of FORD MOTOR CO.
NOTE: Never use a metal hammer on the pinion flange or install the flange with power tools. If necessary, use a plastic hammer to tap on a tight fitting flange while holding the backside of the drive pinion.

Lightly coat the flange splines and seal mating area with lubricant, then install the flange and a new washer and pinion nut.

Fig 19: Locating Flange With Washer And Nut
Courtesy of FORD MOTOR CO.
NOTE: Never back off the pinion nut to reduce preload. If preload reduction is necessary, install a new collapsible spacer and pinion nut.

Tighten the nut.
- Use the Drive Pinion Flange Holding Fixture to prevent the flange from turning while tightening the nut. Remove the Drive Pinion Flange Holding Fixture when taking pinion bearing torque preload readings.
- Rotate the pinion occasionally to verify that the bearings are seating correctly.
- Take frequent pinion bearing torque preload readings.
  
  Fig 20: Locating Pinion Nut And Washer
  Courtesy of FORD MOTOR CO.
Tighten to a rotational torque of 1.7-3.4 Nm (15-30 lb-in).

Fig 21: Measuring Pinion Bearing Torque Preload
Courtesy of FORD MOTOR CO.
Position the differential case with the Dummy Bearing Set into the differential housing.

Fig 22: Placing Dummy Bearing Set On Differential Case Hubs
Courtesy of FORD MOTOR CO.
NOTE: Repeat this step until there is a consistent reading.

Using the Dummy Bearing Set, Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, determine the total thickness of differential bearing shims to install under the differential bearing on the ring gear side of the differential case. Record this measurement, as the shim thickness required for the ring gear side of the differential case.
- Force the ring gear away from the pinion and zero the Dial Indicator Gauge.
- Force the ring gear into mesh with the pinion.
  - Rock the ring gear to allow the teeth of the gears to mesh.
- Record the reading.
  
  Fig 23: Measuring Differential Case End Play Reading
  Courtesy of FORD MOTOR CO.
Remove the differential case and the Dummy Bearing Set from the differential housing.
- Remove the Dummy Bearing Set from the differential case.
  
  Fig 24: Placing Dummy Bearing Set On Differential Case Hubs
  Courtesy of FORD MOTOR CO.

Place the required thickness of differential bearing shims on the ring gear side of the differential case. Refer to the measurement recorded, as the shim thickness required for the ring gear side of the differential case. Differential bearing shims are available in the thickness shown in the following chart.

For example, a reading of 1.14 mm (0.045 in), requires that 1.14 mm (0.045 in) shims be placed on the ring gear side of the differential case.

AVAILABLE DIFFERENTIAL BEARING SHIMS

mm	Inch
0.076	0.003
0.127	0.005
0.254	0.010
0.762	0.030

Using the Differential Carrier Bearing Installer, install the differential bearing.

Fig 25: Installing Differential Bearing On Differential Case
Courtesy of FORD MOTOR CO.
Determine the total thickness of differential bearing shims to install under the differential bearing on the drive pinion side of the differential case.
- Subtract the measurement recorded, as the shim thickness required for the ring gear side of the differential case, from the total case end play measurement taken at the beginning of the assembly procedure. Then, add 0.38 mm (0.015 in) to the total. This is the total amount of differential bearing shims to install under the differential bearing on the drive pinion side of the differential case.
Place the amount of differential bearing shims, as determined by the calculation made in the previous step, on the drive pinion side of the differential case.
Using the Differential Carrier Bearing Installer and Step Plate, install the differential bearing.
1. Place the Step Plate under the bearing to protect it during the bearing installation.
2. Using the Differential Carrier Bearing Installer, install the bearing.
  
  Fig 26: Installing Differential Bearing
  Courtesy of FORD MOTOR CO.
Position the differential bearing cups on the bearings.

Fig 27: Locating Differential Bearing Cups On Bearings
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.

NOTE: Use a safety strap to keep the C-clamp from rotating.

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

Using a C-clamp with the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, spread the differential housing 0.38 mm (0.015 in) and install the differential carrier.
- Remove the Dial Indicator Gauge after measuring the housing spread.
- Using a soft-faced hammer, seat the differential into the differential housing.
  - Remove the C-clamp after seating the differential in the differential housing.
  Fig 28: Seating Differential Into Differential Housing
  Courtesy of FORD MOTOR CO.
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 29: 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, and cannot vary more than 0.05 mm (0.002 in) between points checked.
- Make the necessary corrections by moving shims from one side of the differential case to the other, until the correct backlash adjustment is achieved.
- Correct for low backlash by moving the ring gear away from the pinion.
- Correct for high backlash by moving the ring gear toward the pinion.
  
  Fig 30: Checking Ring Gear And Pinion Backlash
  Courtesy of FORD MOTOR CO.
Apply marking compound and rotate the differential assembly 5 complete revolutions.
Verify an acceptable pattern check. For additional information, refer to DRIVELINE SYSTEM - GENERAL INFORMATION .
NOTE: Clean the differential housing cover mounting surfaces with a suitable solvent to remove all traces of oil film or foreign material.

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 31: Applying Bead Of Silicone Rubber Sealer
Courtesy of FORD MOTOR CO.
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 differential housing cover and the 10 differential cover bolts.
- Tighten to 61 Nm (45 lb-ft).
  
  Fig 32: Locating Differential Housing Cover Bolts
  Courtesy of FORD MOTOR CO.
Position the driveshaft in the front axle flange. Install the 2 new retainers and 4 new flange bolts.
- Tighten to 35 Nm (26 lb-ft).
Install the axle shafts and seals. For additional information, refer to AXLE SHAFT SEAL .
NOTE: If possible, allow one hour curing time before filling the axle with lubricant.

Fill the axle with the specified type and quantity of lubricant.