Differential Ring And Pinion - 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 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.

Fig 1: Locating Driveshaft Flange Bolts

Courtesy of FORD MOTOR CO.

Remove and discard the 4 driveshaft flange bolts and 2 retainers. Position the driveshaft aside.
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: Locating Pinion Flange
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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 Pinion Through Rear Of Differential Housing
Courtesy of FORD MOTOR CO.
Using the Slide Hammer and Bushing Remover, remove the pinion seal. Discard the seal.

Fig 5: Removing Drive Pinion Seal
Courtesy of FORD MOTOR CO.
Remove the oil slinger and the differential pinion bearing.

Fig 6: Locating Differential Pinion Bearing
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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.

Fig 9: Identifying Bolt And Ring Gear

Courtesy of FORD MOTOR CO.

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.