Differential Bearings - Dana 60

Differential Bearings - Dana 60























1. Remove the differential carrier assembly.

2. NOTE: Wire tag the removed outboard spacers. Note from which side they were removed.

Using the special tool, 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. NOTE: 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. NOTE: 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. NOTE: 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 following 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. 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.
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 2 bearing caps.
3) Install the 4 bolts.
^ Tighten to 108 Nm (80 lb-ft).





26. 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 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 damage may 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.





29. NOTE: Always use the same new inner pinion bearing installed when taking the measurement for drive pinion shim selection.

Using the special tool and a suitable press, install the pinion bearing.
^ For semi-float axles, use tool 205-092.





30. NOTE: Use the thickness of the old drive pinion bearing preload shims as a starting point for setting pinion bearing preload.

Inspect the drive pinion bearing preload shims for damage. Discard them if necessary. New shims are available in the thickness shown in the Available Drive Pinion Bearing Preload Shims chart.

Available Drive Pinion Bearing Preload Shims

Available Drive Pinion Bearing Preload Shims:

31. Assemble the drive pinion bearing preload shims onto the pinion and install the pinion into the differential housing.
32. Install the outer pinion bearing.
33. Install the pinion flange.
34. Use the special tool to prevent the flange from turning while installing the old washer and the locknut.
^ Tighten to 339 Nm (250 lb-ft).





35. Using an Nm (lb-inch) torque wrench, rotate the pinion. The torque must read as specified.
^ To increase the preload, remove drive pinion bearing preload shims. To decrease the preload, add shims.





36. Position the differential carrier assembly with the master bearings in the axle housing. Install the special tools and locate the tip of special tool 308-021 on a flat surface.





37. NOTE: Repeat this step and the following step until the same reading appears on the indicator each time. This is the differential bearing shim thickness necessary between the differential case and the differential bearing on the differential ring gear side of the differential case.

Force the differential case away from the drive pinion. With force still applied, set the indicator at 0.





38. Force the differential ring gear into mesh with the pinion, to obtain an indicator reading. Record the reading.





39. Remove the special tools and the differential case from the differential housing.





40. Remove the master bearings from the differential case.
41. Place one shim, of the necessary thickness, as determined from the previous measurement, on the LH side of the differential case. If additional shimming is necessary, beyond what the hardened differential bearing shim can provide, select and install a different thickness outboard spacer.
42. Using the special tool, install the differential bearing on the LH side of the differential case.





43. Determine the correct shim thickness and place it on the differential case hub on the RH side.
^ To determine the correct shim thickness, first, subtract the reading of the previous measurement from the total differential case end play reading. Then, add 0.25 mm (0.010 inch) to this amount. This is the correct thickness shim to place on the hub. If additional shimming is necessary, beyond what the hardened differential bearing shim can provide, select and install a different thickness outboard spacer.
44. Using the special tools, install the differential bearing.
1) Place the special tool on the differential bearing to protect it during the installation of the opposite bearing.
2) Using the special tool, drive the differential bearing onto the hub.





45. Assemble the differential bearing cups to the differential bearings.

46. CAUTION: Do not spread the differential housing more than specified or damage to the component may occur.

Using the special tools, spread the differential housing to the specification.
^ Use a rawhide hammer to seat the differential into the differential housing pocket.
- Remove the special tools.





47. NOTE: Match the mating letters as noted during disassembly.

Install the bearing caps and bolts, aligning the letters with those on the differential housing.
^ Tighten to 108 Nm (80 lb-ft).





48. Confirm the total preload.
^ Using an Nm (lb-inch) torque wrench, check the torque to rotate the pinion. The reading must be higher than the initial reading (taken without the differential case installed) with new bearings installed as recommended by the following:
- 3.54 and 3.73 = 0.9 Nm (8 lb-inch)
- 4.10 and 4.56 = 0.8 Nm (7 lb-inch)
- 4.63 and 5.13 = 0.8 Nm (7 lb-inch)
^ If the total preload is too high, remove an equal amount of differential bearing shims from each differential case hub. If the total preload is too low, add an equal amount of differential bearing shims to each differential case hub.





49. Using the special tools, measure the differential ring gear and pinion backlash at 3 equally spaced points.





50. Carry out the tooth contact pattern check to verify the final pinion position is correct.
51. Install the axle shafts.

52. NOTE: The driveshaft flange yoke fits tightly on the pinion flange pilot. To make sure that the yoke seats squarely on the flange, tighten the bolts evenly in a cross pattern as shown.

Position the driveshaft flange yoke on the pinion flange with the index marks aligned and install the new bolts.
^ Tighten to 112 Nm (83 lb-ft).





53. Fill the axle with the specified type and amount of lubricant.