Differential Ring and Pinion - Dana 60

Differential Ring And Pinion - Dana 60

Special Tool(s) (Part 1):

Special Tool(s) (Part 2):

Special Tool(s) (Part 3):

Material:

Removal

1. Remove the differential carrier.

2. CAUTION: Index-mark the driveshaft to the companion flange to maintain proper driveline balance.





Remove and discard the driveshaft flange bolts. Position the driveshaft aside.
3. Remove and discard the nut and washer.
^ Use the special tool to prevent the flange from turning while removing the nut.





4. Using the special tool, remove the flange.





5. CAUTION: Do not damage the pinion, the bearings or the cup.

Remove the pinion.
^ Using a soft-face hammer, tap the pinion through the outer bearing. Remove the pinion through the rear of the differential housing.





6. Using the special tools, remove the pinion seal. Discard the seal.





7. Remove the oil slinger and the differential pinion bearing.





8. Using the special tools, remove the outer pinion bearing cup, the inner pinion bearing cup and the oil baffle.
^ Use special tool 205-D055 and 205-D051 to remove the inner pinion bearing cup.
^ Use special tool 205-D055 and 205-D054 to remove the outer pinion bearing cup.





9. Remove and discard the collapsible spacer.





10. Place the differential carrier into a vise with soft jaws.
11. Using the special tool, remove the differential bearings.





12. Remove the differential bearing shims.
^ Wire the shims together and mark from which side they were removed.





13. Remove the ring gear.
1 Place the differential into a vise with soft jaws.
2 Remove and discard all but 4 of the bolts. Leave the 4 loosely assembled bolts spaced apart from each other.
3 Tap each bolt head alternately with a soft-face hammer to loosen the ring gear. Remove the bolts and the ring gear.
^ Discard the bolts.





Installation
1. Assemble the ring gear to the differential case by alternately and evenly tightening the new bolts.
^ Tighten to 183 Nm (135 ft. lbs.).





2. Place the special tool on the differential case hubs, and position the assembly into the differential housing.
^ Use special tool 205-D047.





3. NOTE: Use a dial indicator with a minimum travel capacity of 5.08 mm (0.200 inch).

NOTE: Repeat this step until there is a consistent reading.

Determine the total thickness of differential bearing shims to install on the differential case hubs, less the preload, which is calculated later in this procedure. Record this measurement as the total case end play.
1 Position the special tool.
2 Position the special tool.
^ Locate the tip of the tool on a flat surface of one of the ring gear bolt spot faces.
3 Force the ring gear as far as possible toward the special tool.
4 With the pressure still applied, zero the special tool.
5 Force the ring gear as far as it will go in the opposite direction.
6 Record the reading.








4. Remove the differential case with the special tool from the differential housing.
^ Do not remove the special tool from the differential case hubs.





5. Install the inner oil baffle and the inner and outer pinion bearing cups.
1 Position the oil baffle and the bearing cups in the differential housing.
2 Place the special tools on the inner and outer bearing cups.
^ Place special tool 205-006 B1 on the outer pinion bearing cup.
^ Place special tool 205-006 B2 on the inner pinion bearing cup.
3 Install and tighten special tool 205-098 to seat the cups.
^ Remove the special tools after seating the cups.








6. 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.





7. 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 adapter 205-160.
2 Position the adapter 205-105.
3 Position the inner pinion bearing.
4 Position the adapter 205-125.
5 Position the adapter 205-159.
6 Position the outer pinion bearing.
7 Thread on the adapter 205-111.





8. NOTE: This step simulates pinion bearing preload.

Using a Nm (inch lbs.) torque wrench, tighten the special tool to the specification.





9. NOTE: Offset the special tool to obtain an accurate reading.

Rotate the special tool several half-turns to seat the pinion bearings. Position the special tool as shown.





10. Install the special tool.
1 Position the special tool.
^ Use tool 205-D033.
2 Install the bearing caps.
3 Install the bolts.
^ Tighten to 108 Nm (80 ft. lbs.).





11. 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 the gap between the special tools. Record the measurement.
^ Remove the special tools after making the correct shim selection.





12. Notice the (+) or (-) etching on the pinion, and adjust the new shim thickness to compensate for the difference of these 2 figures.
^ For example, a pinion etched with m+8 (+3) requires 0.08 mm (0.003 inch) less shimming than a pinion etched "0". This means to increase the mounting distance by the amount etched in the pinion, subtract 0.08 mm (0.003 inch) from the drive pinion position shim selected for installation. A pinion etched m-8 (-3), requires 0.08 mm (0.003 inch) more shimming than a pinion etched "0". In this instance, add 0.08 mm (0.003 inch) to the drive pinion position shim selected for installation to decrease the pinion mounting distance by the amount etched in the pinion.





13. 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.
^ To change the pinion adjustment, drive pinion position shims are available in the thickness shown in these charts. Measure each shim separately with a micrometer.

Available Drive Pinion Position Shims

Available Drive Pinion Position Shims (Part 1):

Available Drive Pinion Position Shims (Part 2):

14. Using the special tools, install the differential pinion bearing.





15. Using a suitable driver, install the pinion seal.
^ Lightly coat the pinion seal lip with lubricant.





16. Install a new collapsible spacer.





17. CAUTION: Do not damage the pinion, the bearings, the seal or the cup.

Insert the pinion into the differential housing, and seat the inner bearing into the bearing cup.





18. CAUTION: Never use a metal hammer on the pinion flange or install the flange with power tools. If necessary, use a plastic hammer to tap on a tight fitting flange while holding the backside of the drive pinion.

Lightly coat the flange splines and seal mating area with lubricant, then install the flange with a new washer and nut.





19. CAUTION: Never back off the pinion nut to reduce preload. If preload reduction is necessary, install a new collapsible spacer and pinion nut.

Tighten the nut.
^ Use the special tool to prevent the flange from turning while tightening the nut. Remove the special tool when taking pinion bearing torque preload readings.
^ Rotate the pinion occasionally to verify that the bearings are seating correctly.
^ Take frequent pinion bearing torque preload readings.





20. Take frequent pinion bearing torque preload readings.
^ Tighten to a rotational torque of 1.7 - 3.4 Nm (15 - 30 inch lbs.).





21. Position the differential case with the special tool into the differential housing.





22. NOTE: Repeat this step until there is a consistent reading.

Determine the total thickness of differential bearing shims to install under the differential bearing on the ring gear side of the differential case. Record this measurement, as the shim thickness required for the ring gear side of the differential case.
1 Position the special tool.
2 Position the special tool.
3 Force the ring gear into mesh with the pinion.
^ Rock the ring gear to allow the teeth of the gears to mesh.
4 With the pressure still applied, zero the special tool.
5 Force the ring gear away from the pinion.
6 Record the reading.








23. Remove the differential case with the special tool from the differential housing.
^ Remove the special tool from the differential case.





24. Place the required thickness of differential bearing shims on the ring gear side of the differential case. Refer to the measurement recorded, as the shim thickness required for the ring gear side of the differential case. Differential bearing shims are available in the thickness shown in the chart.
^ For example, a reading of 1.14 mm (0.045 inch), requires that 1.14 mm (0.045 inch) shims be placed on the ring gear side of the differential case.

Available Differential Bearing Shims

Available Differential Bearing Shims:

25. Using the special tool(s), install the differential bearing.





26. Determine the total thickness of differential bearing shims to install under the differential bearing on the drive pinion side of the differential case.
^ Subtract the measurement recorded, as the shim thickness required for the ring gear side of the differential case, from the total case end play measurement taken at the beginning of the assembly procedure. Then, add 0.38 mm (0.015 inch) to the total. This is the total amount of differential bearing shims to install under the differential bearing on the drive pinion side of the differential case.
27. Place the amount of differential bearing shims, as determined by the calculation made in the previous step, on the drive pinion side of the differential case.
28. Using the special tools, install the differential bearing.
1 Place the special tool under the bearing to protect it during the bearing installation.
2 Using the special tool, install the bearing.





29. Position the differential bearing cups on the bearings.





30. CAUTION: Do not spread the differential housing more than specified.

CAUTION: Install the C-clamp at the 12 and 6 o'clock positions to allow the horizontal spread of the housing.

CAUTION: Do not damage the ring gear and pinion.

NOTE: Use a C-clamp with a minimum 15 inch opening and a 16,250 lb. load limit.

Using a C-clamp, spread the differential housing 0.38 mm (0.015 inch).
^ Use a soft-face hammer to seat the differential into the differential housing.
^ Remove the C-clamp after seating the differential in the differential housing.





31. CAUTION: Match the positioning of the mating letters on the bearing caps and the differential housing.

Install the bearing caps.
^ Tighten to 108 Nm (80 ft. lbs.).





32. Using the special tools, measure backlash at 3 equally spaced points.
^ The backlash must be within the specifications, and cannot vary more than 0.05 mm (0.002 inch) between points checked.
^ Make the necessary corrections by moving shims from one side of the differential case to the other, until the correct backlash adjustment is achieved.
- Correct for high backlash by moving the ring gear toward the pinion.
- Correct for low backlash by moving the ring gear away from the pinion.





33. Apply marking compound and rotate the differential assembly 5 complete revolutions.
34. Verify an acceptable pattern check.

35. CAUTION: Clean the differential housing cover mounting surfaces with a suitable solvent to remove all traces of oil film or foreign material.

NOTE: The differential housing cover requires the use of silicone sealant material rather than a gasket.

NOTE: Install the differential housing cover within 15 minutes of applying the silicone material.

Apply the specified bead of silicone rubber sealer as shown.





36. CAUTION: Allow one hour curing time before filling the axle with lubricant.

NOTE: Place 2 cover bolts into the differential housing cover at the 2 o'clock and 8 o'clock positions. This will help to position the differential housing cover onto the differential housing.

Install the differential housing cover.
^ Tighten to 47 Nm (35 ft. lbs.).





37. Position the driveshaft in the front axle flange. Install the 4 new flange bolts.
^ Tighten to 35 Nm (26 ft. lbs.).
38. Install the axle shaft assemblies and the front wheel hubs.
39. Fill the axle with the specified type and quantity of lubricant.