Disassembly and Assembly

Special Tools:

Disassembly





1. 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 inch).

NOTE: If differential bearing shims are damaged, replace with new ones.

NOTE: Replace the differential bearings whenever they are removed from the differential case.

Remove the differential bearings with the Pinion and Carrier Bearing Puller.
^ 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).

2. NOTE: Place a few shop towels over the vise to prevent the teeth of the ring gear from being nicked.

Place the differential case in a vise.





3. CAUTION: Use care not to damage the anti-lock speed sensor ring when removing the ring gear. If the anti-lock speed sensor ring is removed, it must be replaced with a new one.

NOTE: Whenever removing the ring gear bolts, always replace them with new bolts upon assembly. Use Grade 9 bolts for service replacement for all Dana rear axles.

Remove the bolts on the ring gear. Leave four bolts loosely assembled, 90 degrees apart.





4. Tap each bolt head alternately with a rawhide or plastic hammer to loosen the ring gear. Remove the bolts and the ring gear.





5. If required, remove the anti-lock speed sensor ring with a soft-faced hammer. Discard the anti-lock speed sensor ring.





6. Place the differential case in a vise. Use a small drift to drive out the differential pinion shaft lock pin that secures the differential pinion shaft.





7. Remove the differential pinion shaft using a drift.





8. Remove the differential pinion gears and the differential pinion thrust washers by rotating the differential pinion gears to the opening of the differential case.
9. Lift out the differential side gears and the differential side gear thrust washers.

Assembly
1. Place the differential case in a vise.
2. Apply Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B to the new differential side gear thrust washers, the rear hubs, the thrust face of the new differential side gears, the new differential pinion thrust washers and the new differential pinion gears.
3. Lubricate the differential side gears and differential pinion gears with High Performance Synthetic 75-W140 Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.





4. Assemble both differential side gears and differential side gear thrust washers. While holding them in place, assemble the differential pinion gears and differential pinion thrust washers to hold the differential side gears in place.





5. Rotate the differential pinion gears until the pinion shaft bore in the case and gears align.
^ 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.
^ If necessary, use a drift to line up the holes.





6. Install the differential pinion shaft, aligning the lock pin hole in the differential pinion shaft and the differential case.





7. Install the differential pinion shaft lock pin.
^ Peen the metal of the differential case over the differential pinion shaft lock pin in two places, 90 degrees from the slot in the differential pinion shaft lock pin.





8. NOTE: The tab on the anti-lock speed sensor ring must be aligned with the slot in the differential case.

Align the tab in the anti-lock speed sensor ring with the slot in the differential case. Start the two ring gear bolts through the differential case flange into the ring gear to make sure the differential case and the ring gear bolt holes align.





9. Press the anti-lock speed sensor ring on the differential case. The differential case flange acts as a pilot for the anti-lock speed sensor ring.





10. Apply Treadlock(R) and Sealer E0AZ-19554-AA or equivalent meeting Ford specification WSK-M2G315-A5 (TYPE II) to the new ring gear bolts. Draw up the Grade 9 ring gear bolts alternately and evenly.

11. NOTE: Refer to Differential Case and Pinion Set Up.

Install the differential bearings.