Differential Carrier - Dana 60

Differential Carrier - Dana 60

















Removal

All axles

1. Remove the axle shafts. For additional information, refer to Axle Shaft - Semi-Floating Axle Rear Drive Axle/Differential - Dana 60 and 70 or Axle Shaft - Full Floating Axle in Differential Assembly.

Full-floating axle

2. Remove the differential housing cover. For additional information, refer to Differential Housing Cover Service and Repair.

All axles

3. NOTE: Note the positions of the mating letters stamped vertically and horizontally on the bearing caps and the differential housing before removing the bearing caps. Matching the letters is important at the time of installation.

To ease removal of the differential assembly, loosen the bolts, then pry the differential case, bearing cups and outboard spacers outward until they are loose in the differential housing.





4. Remove the 4 bolts and the 2 bearing caps.

5. NOTICE: Do not spread the differential housing more than specified or damage to the housing may occur.

Using the Dial Indicator Gauge with Holding Fixture and Differential Carrier Spreader, spread the differential housing to the specification. Remove Dial Indicator after spreading the housing.





6. NOTICE: It will be necessary to use large pry bars to remove the differential carrier from the differential housing. Do not damage the differential ring rear when carrying out this step.

NOTE: Mark or tag the differential bearing cups, indicating from which side they were removed.

Remove the differential assembly with the 2 bearing cups.





7. NOTE: Mark or tag the outboard spacers indicating from which side they were removed.

Remove the outboard spacers.





Installation

All axles

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

2. NOTICE: Do not spread the differential housing more than specified or damage to the housing may occur.

Using the Dial Indicator Gauge with Holding Fixture and Differential Housing Spreader, spread the differential housing to the specification.

- Use a rawhide hammer to seat the differential and outboard spacers into the differential housing pocket.
- Remove the Dial Indicator and Differential Housing Spreader.





3. NOTE: Match the mating letters as noted during removal.

Install the 2 bearing caps and the 4 bearing cap bolts, aligning the letters with those on the differential housing.

- Tighten to 108 Nm (80 lb-ft).





4. Using the Dial Indicator Gauge and Clutch Housing Gauge, measure the differential ring gear and pinion backlash at 3 equally spaced points.





Full-floating axle

5. Install the differential housing cover. For additional information, refer to Differential Housing Cover Service and Repair.

All axles

6. Install the axle shafts. For additional information, refer to Axle Shaft - Semi-Floating Axle Rear Drive Axle/Differential - Dana 60 and 70 or Axle Shaft - Full Floating Axle in Differential Assembly.