Differential Carrier - Dana 60: Removal

WARNING: This page is about a different car, the 2012 Ford Pickup, 2012 Ford F550 Super Duty, 2012 Ford F450 Super Duty, and 2012 Ford Cab & Chassis. 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: Identifying Tie-Rod End
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.

Fig 2: Locating Mating Letters Position On Bearing Caps And Differential Housing

Courtesy of FORD MOTOR CO.

Remove the 4 bolts and the 2 bearing caps.

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.

Fig 3: Removing Dial Indicator Gauge (View 1 Of 2)

Courtesy of FORD MOTOR CO.

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.
Using a pry bar, remove the differential with the bearing cups.
- Remove the C-clamp after removing the differential.