Differential Case and Ring Gear - Conventional
Differential Case and Ring Gear - Conventional
Disassembly
All axles
1. Remove the differential carrier. For additional information, refer to Differential Carrier - Dana 60 Differential Carrier - Dana 60 or Differential Carrier - Dana 70 Differential Carrier - Dana 70.
2. NOTE: Differential bearing shims are available in thicknesses of 0.762, 0.787, 0.813, 0.838, 0.864, 0.889 and 0.914 mm (0.030, 0.031, 0.032, 0.033, 0.034, 0.035 and 0.036 in).
NOTE: If differential bearing shims are damaged, install new ones.
NOTE: Install new differential bearings whenever they are removed from the rear axle differential carrier.
Using the Drive Pinion/Differential Carrier Puller, remove the differential bearings.
- Wire the differential bearing shims, differential bearing cup, differential bearing and outboard selective spacer together. Note from which side they were removed (ring gear side or opposite side).
3. NOTE: Use a vise with brass jaws or wood blocks.
Place the differential case in a vise.
4. NOTE: Whenever removing the ring gear bolts, always install new bolts upon assembly. Use Grade 9 bolts for service replacement for all Dana rear axles.
Remove and discard the bolts on the ring gear. Leave 4 bolts loosely assembled, 90 degrees apart.
5. Tap each bolt head alternately with a rawhide or plastic hammer to loosen the ring gear. Remove the bolts and the ring gear.
Full-float axles
6. NOTE: Use a vise with brass jaws or wood blocks.
Place the differential case in a vise. Using a small drift, drive out the differential pinion shaft lockpin that secures the differential pinion shaft.
Semi-float axles
7. NOTICE: The semi-float axle differential assembly is equipped with either a Loctite(R) coated differential pinion shaft lock screw or a differential pinion shaft lock screw with torque prevailing threads. The Loctite(R) treated differential pinion shaft lock screw has a 5/32-in hexagram socket head. Never, under any circumstance, reuse a Loctite(R) coated screw after removing it. Always discard the screw and install a new one. The torque prevailing differential pinion shaft lock screw has a 12-point drive head. This type of screw is reusable for no more than 4 installations. When in doubt of the number of installations of a torque prevailing differential pinion shaft lock screw, discard it and install a new one or damage to the component may occur.
Remove the differential pinion shaft lock screw.
All axles
8. Using a drift, remove the differential pinion shaft.
9. To remove the differential side gears and the differential pinion gears, rotate the differential side gears. The differential pinion gears will turn to the opening of the differential case.
10. Remove the differential pinion gears and the differential pinion gear thrust washers behind the differential pinion gears.
11. Lift out the differential side gears and the differential side gear thrust washers.
Assembly
All axles
1. NOTE: Use a vise with brass jaws or wood blocks.
Place the differential case in a vise.
2. Apply grease to the new differential side gear thrust washers and to the thrust face of the new differential side gears.
3. Apply grease to the new differential pinion thrust washers and the new differential pinion gears.
4. Lubricate the differential side gears and differential pinion gears with the specified lubricant. Refer to Specifications for the correct type.
5. Assemble both differential side gears and differential side gear thrust washers. Hold the assembly in place by hand, then assemble the differential pinion gears and differential side gear thrust washers to hold the differential side gears in place.
6. NOTE: Rotate the differential side gears until the holes of the differential side gear thrust washers and the differential pinion gears line up with the holes of the differential case. If the differential pinion gears cannot be rotated by hand, install one of the axle shafts into the spline of the differential side gear and use a pipe wrench to turn the axle shaft.
Using a drift, line up the holes with those of the differential case.
7. Assemble the differential pinion shaft and drive on the differential pinion shaft to remove the drift. Align the lockpin hole of the differential pinion shaft with the lockpin hole of the differential case.
Full-float axles
8. Assemble the differential pinion shaft lockpin. Peen the metal of the differential case over the differential pinion shaft lockpin in 2 places, 180 degrees apart, to lock in place. Note the location of the slot in the differential pinion shaft lockpin and peen 90 degrees away.
Semi-float axles
9. NOTICE: The semi-float axle differential assembly is equipped with either a Loctite(R) coated differential pinion shaft lock screw or a differential pinion shaft lock screw with torque prevailing threads. The Loctite(R) treated differential pinion shaft lock screw has a 5/32-in hexagram socket head. Never, under any circumstance, reuse a Loctite(R) coated screw after removing it. Always discard the screw and install a new one. The torque prevailing differential pinion shaft lock screw has a 12-point drive head. This type of screw is reusable for no more than 4 installations. When in doubt of the number of installations of a torque prevailing differential pinion shaft lock screw, discard it and install a new one or damage to the component may occur.
Install the pinion shaft and pinion shaft lock screw finger-tight to prevent the differential side gears and differential pinion gears from rotating and falling out of the differential case.
All axles
10. Start the 2 new ring gear bolts through the differential case flange into the ring gear to make sure the differential case and the ring gear bolt hole align.
11. Apply threadlock to the 12 new ring gear bolts.
12. Install and tighten the Grade 9 ring gear bolts alternately and evenly.
- Tighten to 215 Nm (158 lb-ft).
13. Install the differential bearings. For additional information, refer to Differential Bearings - Dana 60 Differential Bearings - Dana 60 or Differential Bearings - Dana 70 Differential Bearings - Dana 70.
14. Install the differential carrier. For additional information, refer to Differential Carrier - Dana 60 Differential Carrier - Dana 60 or Differential Carrier - Dana 70 Differential Carrier - Dana 70.