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Differential Bearings - Dana 60: Installation

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  1. Place the Dummy Bearing Set on the differential case hubs and position the assembly into the differential housing.
    Fig 1: Locating Dummy Bearing Set Into Differential Housing
    G06777456Courtesy of FORD MOTOR CO.
    2. NOTE: Repeat this step until there is a consistent reading.
    Fig 2: Identifying Total Thickness Of Differential Bearing Shims
    G06777457Courtesy of FORD MOTOR CO.
  2. Determine the total thickness of the differential bearing shims to install on the differential case hubs, less the preload, which is calculated later in this procedure. Record this measurement as the total case end play.
    • Locate the tip of the Clutch Housing Gauge on a flat surface of one of the ring gear bolt spot faces. Force the ring gear as far as possible to the ring gear side and zero the Dial Indicator Gauge.
    3. NOTE: Repeat this step until there is a consistent reading.
    Fig 3: Identifying Total Differential End Play Reading
    G06777458Courtesy of FORD MOTOR CO.
  3. Force the differential assembly as far as it will go toward the pinion side. Record the reading as total differential end play.
  4. 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 4: Locating Dummy Bearing Set Into Differential Housing
    G06777456Courtesy of FORD MOTOR CO.
    5. NOTE: Make sure the inner oil baffle is squarely under the inner pinion bearing cup.
  5. Install the inner oil baffle and the inner and outer pinion bearing cups.
  6. Using the Rear Axle Drawbar and Drive Pinion Bearing Cup Installers, install the pinion bearing cups.
    • Place the Drive Pinion Bearing Cup Installer 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 5: Identifying Rear Axle Drawbar
    G06777460Courtesy of FORD MOTOR CO.
    7. 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.
    Fig 6: Checking Clearance Between Cup And Bore
    G06125142Courtesy of FORD MOTOR CO.
  7. Check that the cups have seated correctly in their bores.
    8. 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.
    Fig 7: Assembling Pinion Bearings Using Special Tools
    G06142649Courtesy of FORD MOTOR CO.
  8. 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.
    9. NOTE: This step simulates pinion bearing preload.
    Fig 8: Checking Differential Pinion Bearing Preload
    G06125144Courtesy of FORD MOTOR CO.
  9. 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).
    10. NOTE: Offset the Adapter to obtain an accurate reading.
    Fig 9: Identifying Adapter Position
    G06125145Courtesy of FORD MOTOR CO.
  10. Rotate the Adapter several half-turns to seat the pinion bearings. Position the Adapter as shown in illustration.
  11. Install the Gauge Tube.
    1. Install the 2 bearing caps.
    2. Install the 4 bolts.
      • Tighten to 108 Nm (80 lb-ft).
    Fig 10: Identifying Gauge Tube
    G06777465Courtesy of FORD MOTOR CO.
    12. 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.
    Fig 11: Locating Drive Pinion Position Shims And Feeler Gauge
    G06777466Courtesy of FORD MOTOR CO.
  12. Using a feeler gauge or flat, clean drive pinion position shims, measure the gap between the Adapter and Gauge Tube. Record the measurement.
  13. 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 12: Identifying Matching Numbers Of Differential Ring Gear And Pinion
    G07968119Courtesy of FORD MOTOR CO.
    14. NOTE: Follow the drive pinion bearing preload shim and drive pinion position shim assembly sequence as directed or unit failure can result.
  14. 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
  15. Using the Bearing Oil Seal Plate and Rear Axle Bearing/Oil Seal Installer, install the selected pinion bearing shim and the differential pinion bearing.
    Fig 13: Installing Selected Pinion Bearing Shim And Differential Pinion Bearing
    G06777527Courtesy of FORD MOTOR CO.
  16. Using a suitable driver, install the pinion seal.
    • Lightly coat the pinion seal lip with axle lubricant.
    Fig 14: Installing Pinion Seal
    G06777401Courtesy of FORD MOTOR CO.
  17. Install a new collapsible spacer.
    Fig 15: Locating Collapsible Spacer
    G07968122Courtesy of FORD MOTOR CO.
    18. NOTE: Do not damage the pinion, the bearings, the seal or the cup.
    Fig 16: Inserting Pinion Into Differential Housing
    G07968123Courtesy of FORD MOTOR CO.
  18. Insert the pinion into the differential housing and seat the inner bearing into the bearing cup.
    19. 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.
    NOTE: If reusing the original pinion and flange, align the index marks made during disassembly.
    Fig 17: Installing Flange With New Washer And Nut
    G07968059Courtesy of FORD MOTOR CO.
  19. Lightly coat the flange splines and seal mating area with lubricant, then install the flange and a new pinion washer and pinion nut.
    20. NOTE: Never back off the pinion nut to reduce preload. If preload reduction is necessary, install a new collapsible spacer and pinion nut.
    Fig 18: Locating Flange Nut And Washer
    G06777398Courtesy of FORD MOTOR CO.
  20. 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.
  21. Tighten to a rotational torque of 1.7-3.4 Nm (15-30 lb-in).
    Fig 19: Checking Frequent Pinion Bearing Torque Preload
    G07968054Courtesy of FORD MOTOR CO.
  22. Position the differential case with the Dummy Bearing Set into the differential housing.
    Fig 20: Locating Dummy Bearing Set Into Differential Housing
    G06777456Courtesy of FORD MOTOR CO.
    23. NOTE: Repeat this step until there is a consistent reading.
    Fig 21: Measuring Total Thickness Of Differential Bearing Shims
    G06777457Courtesy of FORD MOTOR CO.
  23. Using the 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.
  24. Remove the differential case and the Dummy Bearing Set from the differential housing.
    • Remove the Dummy Bearing Set from the differential case.
    Fig 22: Locating Dummy Bearing Set Into Differential Housing
    G06777456Courtesy of FORD MOTOR CO.
  25. 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 (0.043 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
  26. Using the Differential Carrier Bearing Installer, install the differential bearing.
    Fig 23: Installing Differential Bearing On Differential Case
    G06776626Courtesy of FORD MOTOR CO.
  27. 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.
  28. 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.
  29. 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 24: Installing Differential Bearing
    G06777479Courtesy of FORD MOTOR CO.
  30. Position the differential bearing cups on the bearings.
    Fig 25: Positioning Differential Bearing Cups On Bearings
    G07968132Courtesy of FORD MOTOR CO.
    31. NOTE: Do not spread the differential housing more than specified or damage to the housing can 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.
    Fig 26: Installing Differential Carrier
    G06777481Courtesy of FORD MOTOR CO.
  31. Using a C-clamp with the Dial Indicator Gauge 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.
    • Use a soft-faced hammer to seat the differential into the differential housing.
      • Remove the C-clamp after seating the differential in the differential housing.
    32. NOTE: Match the positioning of the mating letters on the bearing caps and the differential housing.
    Fig 27: View Of Mating Letters On Bearing Caps And Differential Housing
    G06776629Courtesy of FORD MOTOR CO.
  32. Install the 2 bearing caps and 4 bolts.
    • Tighten to 108 Nm (80 lb-ft).
  33. 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 28: Measuring Differential Ring Gear Backlash
    G06125695Courtesy of FORD MOTOR CO.
  34. Apply marking compound and rotate the differential assembly 5 complete revolutions.
  35. Verify an acceptable pattern check. For additional information, refer to DRIVELINE SYSTEM - GENERAL INFORMATION .
    36. 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.
    Fig 29: Applying Bead Of Silicone Rubber Sealer
    G07968136Courtesy of FORD MOTOR CO.
  36. Apply the specified bead of silicone rubber sealer as shown in illustration.
    37. 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.
    Fig 30: Locating Differential Housing Cover Bolts
    G06142868Courtesy of FORD MOTOR CO.
  37. Install the differential housing cover and the 10 differential cover bolts.
    • Tighten to 61 Nm (45 lb-ft).
  38. 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).
  39. Install the axle shafts and seals. For additional information, refer to Axle Shaft Seal .
    40. NOTE: If possible, allow one hour curing time before filling the axle with lubricant.
  40. Fill the axle with the specified type and quantity of lubricant.
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