Front

Special Tools:

Disassembly

1. CAUTION: Replace the bearings whenever their removal from the differential case is necessary.





Remove the differential bearings and the shims.
1. Place the differential into a vise with soft jaws.
2. Remove the differential bearing, using the Pinion and Carrier Bearing Puller. Discard the bearing.





3. CAUTION: Replace any damaged shims at time of assembly.

Remove the differential bearing shims.
^ Wire the shims, the bearing cone and the cup together. Identify from which side they were removed.
- Repeat the procedure for the opposite side.

2. CAUTION:
^ Whenever removing the ring gear bolts, always replace them with new bolts upon assembly.
^ Place shop towels under the ring gear to prevent ring gear damage.





Remove the ring gear.
1. Place the differential case into a vise with soft jaws.
2. Remove and discard all but four of the retaining bolts. Leave four 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.





3. Drive out the differential pinion shaft lock pin, using a small drift.





4. Remove the differential pinion shaft.





5. Remove the differential pinion gears and thrust washers, and the differential side gears and thrust washers.

6. CAUTION:
^ Always use new solvent when cleaning bearings.
^ Do not spin dry bearings with compressed air.
^ Oil the bearings immediately, to prevent rusting.
^ If upon inspection, any component has score marks/chips, thoroughly clean the axle housing.

Perform the following inspection.
^ Thoroughly clean all parts.
^ Inspect all parts for damage.
^ Replace the complete differential if excessive wear is visible on all parts.
^ Replace the differential pinion and side gears as a set if gear replacement is necessary.
^ Make sure the differential bearing bores are smooth. Remove any nicks/burrs from the mounting surfaces of the axle housing.

Assembly
1. Place the differential case into a vise with soft jaws.
2. Apply High Temperature 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590-A or equivalent meeting Ford specification ESA-M1C198-A to the following.
^ The differential side gear thrust washers.
^ The differential side gear hubs and thrust faces.
^ The differential pinion thrust washers.
^ The differential pinion gears.
^ Assemble the gears and their respective washers.





3. Lubricate the gears with SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A, and install them into the differential case.
^ Install and hold the differential side gears and thrust washers in the differential case. Then, install the differential pinion gears and thrust washers, and rotate them until the pinion shaft bore in the case and gears align.
^ If hand rotation of the gears is not possible, install an axle shaft into the differential side gear, and turn the shaft with a pipe wrench.
^ If necessary, use a drift to align the pinion shaft bores.





4. Install the differential pinion shaft, aligning the lock pin bore in the differential case and the pinion shaft.





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





6. On Dana model 50 axles, assemble the ring gear to the differential case, and alternately and evenly tighten the new bolts.





7. On Dana model 60 axles, assemble the ring gear to the differential case, and alternately and evenly tighten the new bolts.
8. Install the differential bearings only after determining the appropriate amount of differential bearing shims to install.