Rear Drive Axle/Differential - Dana 60 and 70
Axle Shaft - Semi-Floating AxleMaterial:
Removal
1. Raise the vehicle on a hoist or raise the rear end of the vehicle with a jack. Install safety stands under the frame rails and lower the jack or hoist enough to allow the rear axle to drop into the rebound position for working clearance. For additional information, refer to Maintenance/Service and Repair.
2. Remove the rear wheel and tire assembly.
3. Remove the brake disc.
4. Remove the differential housing cover and drain the lubricant.
^ Clean the gasket material from the differential housing cover and the differential housing.
5. CAUTION: The differential assembly is equipped with a differential pinion shaft lock screw with torque prevailing threads. 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 about the number of installations of a torque prevailing differential pinion shaft lock screw, discard it and install a new screw.
Remove the lock screw.
6. Remove the differential pinion shaft.
^ The pinion shaft is a slip-fit design and is removable by hand.
7. Push the flanged end of the axle shaft toward the center of the axle and remove the U-washer.
8. CAUTION: Do not damage the wheel bearing oil seal when removing the axle shaft.
CAUTION: Do not rotate the differential side gears when removing the axle shaft. Rotating the differential side gears causes the differential pinion gears and differential pinion thrust washers to turn to the differential case opening and fall out of the differential case.
Remove the axle shaft.
9. CAUTION: Install the differential pinion shaft and the old lock screw (finger-tight) to prevent the differential side gears and differential pinion gears from rotating and falling out of the differential case.
Install the differential pinion shaft and the old lock screw in the differential case.
Installation
1. Remove the lock screw and the differential pinion shaft.
2. CAUTION: Do not damage the wheel bearing oil seal when installing the axle shaft.
Push the axle shaft into the axle tube and engage the differential side gear with the shaft splines.
3. Push the axle shaft toward the center of the axle and install the U-washer. Pull the axle shaft outward until the U-washer locks into the differential side gear.
4. Align the differential pinion shaft lock screw hole with the hole in the differential case. Correctly position the differential pinion thrust washers. Install the differential pinion shaft.
5. NOTE: The threads in the differential case and on the lock screw must be free of dirt and oil.
Install the new lock screw.
^ Tighten to 27 Nm (20 ft. lbs.)
6. CAUTION: Clean the mounting surface on the differential housing cover and the differential housing with a suitable solvent to remove all traces of oil film.
CAUTION: The differential housing cover uses silicone rubber sealant material as a gasket. Install the differential housing cover within 15 minutes of applying the silicone or it will be necessary to apply new sealant.
Apply a continuous bead of silicone sealant to the differential housing cover mounting surface.
7. Assemble 2 bolts into the differential housing cover at the 8 o'clock and 2 o'clock positions. Using the 2 bolts as a guide, position the differential housing cover on the differential housing.
8. Install the remaining bolts. Tighten the bolts alternately and evenly.
^ Tighten Grade 5 bolts to 47 Nm (35 ft. lbs.)
^ Tighten Grade 8 bolts to 61 Nm (45 ft. lbs.)
9. CAUTION: Allow one hour cure time before filling the axle with the correct amount of specified lubricant and operating the vehicle.
CAUTION: For limited-slip axles, first fill the axle with 0.15 L (6 oz) of friction modifier.
Fill the differential housing with 2.8 L (5.9 pt) of the specified rear axle lubricant.
10. Install the brake disc.
11. Install the wheel and tire assembly.
12. Lower the vehicle.