Part 1
Differential Bearings - Dana 60Special Tool(s):
Special Tool(s):
Special Tool(s):
Special Tool(s):
Material:
Steps 1-28
1. Remove the differential carrier assembly.
2. NOTE: Wire tag the removed outboard spacers. Note from which side they were removed.
Using the special tools, remove the differential bearings.
^ Place the left and right differential bearing shims with the respective outboard spacers.
3. To maintain driveline balance, index-mark the driveshaft flange yoke and the pinion flange.
4. Remove the 4 bolts.
5. CAUTION: The driveshaft flange yoke fits tightly on the pinion flange yoke. Never hammer on the driveshaft or any of its components to disconnect the yoke from the flange. Pry only in the area shown, with a suitable tool, to disconnect the yoke from the flange.
Using a suitable tool as shown, disconnect the driveshaft flange yoke from the pinion flange and support the driveshaft using mechanic's wire.
6. CAUTION: Index-mark the pinion flange to the pinion shaft prior to removal.
Use the special tool to prevent the flange from turning while removing the locknut and washer.
7. Using the special tool, remove the pinion flange.
8. NOTE: There are drive pinion bearing preload shims on the spline-end of the pinion. These shims and spacer can stick to the pinion, the pinion bearing, or they can fall out of the differential housing. Collect and keep the shims for reassembly.
Using a soft-face hammer, tap the pinion out of the pinion bearing cup and remove it through the rear of the differential housing.
9. Using the special tools, remove and discard the pinion seal.
10. Remove the oil slinger and the pinion bearing.
11. CAUTION: Do not nick the differential housing bore.
Using the special tools, remove the outer pinion bearing cup.
^ For semi-float axles, use tools 205-D054 and 205-D055.
12. Using the special tools, remove the inner pinion bearing cup.
^ For semi-float axles, use tools 205-D051 and 205-D055.
13. Using the special tool, remove the inner pinion bearing.
14. NOTE: Discard the drive pinion position shim if bent or nicked. If discarding the shim, measure and record the shim thickness.
Remove the drive pinion position shim.
15. Position the inner and outer pinion bearing cups and the special tools in their respective differential housing bores.
1 After placing the inner and outer pinion bearing cups in their bores, place the special tool (inner) on the inner pinion bearing cup.
2 Place the special tool (outer) on the outer pinion bearing cup.
3 Install the special tool.
16. Tighten the special tool to seat the pinion bearing cups into their bores.
17. 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.
18. Install the outboard spacers in the side from which they were removed.
19. NOTE: Remove all nicks, burrs and dirt from the differential case hubs, to allow the bearings to rotate freely.
Place the special tool on the differential case hubs and position the assembly into the differential housing.
^ For semi-float axles, use tool 205-D047.
20. NOTE: Use a dial indicator with a minimum travel capability of 5.08 mm (0.200 inch).
NOTE: The rear axle uses a combination of differential bearing shims and selective outboard spacers to control differential case end play. The old outboard spacers provide a good starting point when setting end play.
However, if additional shimming is necessary, beyond what the hardened differential bearing shims can provide, select and install different thickness outboard spacers.
Mount the special tools as shown. Locate the tip of special tool 308-021 on a flat surface on one of the bolts.
21. NOTE: Repeat this step and the next step until the same reading appears on the indicator each time. Record the reading. This is the total differential bearing shim thickness required, less preload. The final calculation occurs later during assembly.
Force the differential case as far as possible toward the indicator. With force still applied, set the indicator at 0.
22. Force the differential case as far as it will go in the opposite direction. Record the total differential case end play reading.
23. After making sure the reading is correct, remove the special tools and the differential from the differential housing. Do not remove the master bearings from the differential case at this time.
24. CAUTION: 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 these in the differential housing.
1 Position the special tool.
2 Position the special tool.
3 Position the inner pinion bearing.
4 Position the special tool.
5 Position the special tool.
6 Position the outer pinion bearing.
7 Thread on the special tool.
25. Install the special tool.
1 Position the special tool.
^ For semi-float axles, use tool 205-D033.
2 Install the bearing caps.
3 Install the bolts.
^ Tighten to 108 Nm (80 ft. lbs.)
26. NOTE: Use a feeler gauge or flat, clean drive pinion position shims as a measuring devise.
NOTE: Do not attempt to force the gauge or shim between the special tools. A slight drag indicates a correct selection.
Using a feeler gauge or flat, clean drive pinion position shims, measure between the special tools. Record the measurement. Refer to Pinion Ring Gear Variation Number for shim selection information.
^ Remove the special tools after making the correct shim selection.
27. CAUTION: 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.
28. If the pinion bearing preload is within specification and the pinion position shim has changed, change the drive pinion bearing preload shims by the same amount.
^ The direction arrow pointing toward the pinion flange indicates that by removing the drive pinion position shim, the distance from the centerline of the tubes to the pinion backface increases, giving a plus (+) reading. The drive pinion bearing preload shim pack does not affect the pinion depth setting. However, if the pinion position is changed, the pinion preload will change and may require adjustment to bring the torque-to-rotate within specification. Arrows on the ring gear illustrate the method to increase or decrease backlash and differential bearing preload.
