Differential Ring And Pinion - Dana 60

Differential Ring And Pinion - Dana 60





























1. Remove the differential carrier assembly. For additional information, refer to Differential Carrier - Dana 60 Differential Carrier - Dana 60.

2. NOTE: Mark or tag the outboard spacers indicating from which side they were removed.

Remove the 2 outboard spacers.

- Inspect the spacers for nicks, bending and grooved conditions. Discard them if necessary.





3. Using the Drive Pinion/Differential Carrier Puller, remove the 2 differential bearings.
- Place the left and right differential bearing shims with the respective outboard spacers.





4. NOTE: Use a vise with brass jaws or wood blocks.

Place the differential case in a vise.

5. 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 8 of the bolts on the ring gear. Leave 4 bolts loosely assembled, 90 degrees apart.





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





7. To maintain driveline balance, index-mark the driveshaft flange yoke and the pinion flange.





8. Remove the 4 bolts.





9. NOTE: The driveshaft flange yoke fits tightly on the pinion flange yoke. Never hammer on the driveshaft or any of its components to disconnect the yoke from the flange. Pry only in the area shown, with a suitable tool, to disconnect the yoke from the flange.

Using a suitable tool as shown, disconnect the driveshaft flange yoke from the pinion flange and support the driveshaft using mechanic's wire.





10. NOTE: Index-mark the pinion flange to the pinion shaft prior to removal.

Use the Drive Pinion Flange Holding Fixture to prevent the flange from turning while removing the locknut and washer.





11. Using the 2-Jaw Puller, remove the pinion flange.





12. NOTE: There are drive pinion bearing preload shims on the spline-end of the pinion. These shims can stick to the pinion, the pinion bearing, or they can fall out of the differential housing. Collect and keep the shims for reassembly.

Using a soft-face hammer, tap the pinion out of the pinion bearing cup and remove it through the rear of the differential housing.





13. Using the Bushing Remover and Slide Hammer, remove and discard the pinion seal.





14. Remove the oil slinger and the pinion bearing.

15. NOTICE: Do not nick the differential housing bore.

Remove the outer pinion bearing cup.

16. Remove the inner pinion bearing cup.

17. Using the Drive Pinion/Differential Carrier Puller, remove the inner pinion bearing.





18. NOTE: Discard the drive pinion position shim if bent or nicked. If discarding the shim, measure and record the shim thickness.

Remove the drive pinion position shim.

19. Position the inner and outer pinion bearing cups and the Drive Pinion Bearing Cup Installer in their respective differential housing bores.

1. After placing the inner and outer pinion bearing cups in their bores, place the Drive Pinion Bearing Cup Installer (inner) on the inner pinion bearing cup.

2. Place the Drive Pinion Bearing Cup Installer (outer) on the outer pinion bearing cup.

3. Install the Drive Pinion Bearing Cup Installer.





20. Tighten the Drive Pinion Bearing Cup Installer to seat the pinion bearing cups into their bores.





21. 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.





22. Start the 2 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.





23. Press the ring gear on the differential case. The differential case flange acts as a pilot for the ring gear.





24. Apply threadlock to the 12 new ring gear bolts.

25. Install and tighten the Grade 9 ring gear bolts alternately and evenly.
- Tighten to 176 Nm (130 lb-ft).





26. Install the 2 outboard spacers in the side from which they were removed.





27. Place the Master Bearing Set on the differential case hubs and position the assembly into the differential housing.
- For semi-float axles, use tool 205-D047.





28. NOTE: Use a dial indicator with a minimum travel capability of 5.08 mm (0.200 in).

NOTE: The rear axle uses a combination of differential bearing shims and selective outboard spacers to control differential case end play. The old outboard spacers provide a good starting point when setting end play. However, if additional shimming is necessary, beyond what the hardened differential bearing shims can provide, select and install different thickness outboard spacers.

Mount the Dial Indicator Gauge with Holding Fixture as shown. Locate the tip of Clutch Housing Gauge on a flat surface on one of the bolts.





29. NOTE: Repeat this step and the following step until the same reading appears on the indicator each time. Record the reading. This is the total differential bearing shim thickness required, less preload. The final calculation occurs later during assembly.

Force the differential case as far as possible toward the indicator. With force still applied, set the indicator at 0.





30. Force the differential case as far as it will go in the opposite direction. Record the total differential case end play reading.





31. After making sure the reading is correct, remove the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge and the differential from the differential housing. Do not remove the master bearings from the differential case at this time.





32. NOTE: Apply only a light oil film on the pinion bearings before assembling the tools.

Assemble and position the following in the differential housing.

1. Position the Adapter.

2. Position the Alignment Adapter.

3. Position the inner pinion bearing.

4. Position the Gauge Disc.

5. Position the Adapter.

6. Position the outer pinion bearing.

7. Thread on the Adapter.





33. NOTE: This step simulates pinion bearing preload.

Using a Nm (lb-in) torque wrench, tighten the Adapter Handle to specification.

- Tighten to 2.26-5.09 Nm (20-45 lb-in).

34. NOTE: Offset the Adapter as shown to obtain an accurate reading.

Rotate the Adapter several half-turns to seat the pinion bearings and position the Adapter as shown.





35. Install the Gauge Tube.

1. Position the Gauge Tube.
- For semi-float axles, use tool 205-D033.

2. Install the 2 bearing caps.

3. Install the 4 bolts.

- Tighten to 108 Nm (80 lb-ft).





36. NOTE: Using a feeler gauge or flat, clean drive pinion, position shims as a measuring devise.

NOTE: Do not attempt to force the gauge or shim between the Adapter and Gauge Tube. A slight drag indicates a correct selection.

Using a feeler gauge or flat, clean drive pinion position shims, measure between the Adapter and Gauge Tube. Record the measurement.

- Remove the Adapter and Gauge Tube after making the correct shim selection.





37. Notice the (+) or (-) etching on the pinion and adjust the new shim thickness to compensate for preferred running depth.
- For example, a pinion etched with m+8 (+3) requires 0.08 mm ( 0.003 in) 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 in) from the drive pinion position shim selected for installation. A pinion etched m-8 (-3), requires 0.08 mm (0.003 in) more shimming than a pinion etched "0". In this instance, add 0.08 mm (0.003 in) to the drive pinion position shim selected for installation to decrease the pinion mounting distance by the amount etched in the pinion.

38. NOTICE: Follow the drive pinion bearing preload shim and drive pinion position shim assembly sequence as directed or unit damage can result.

Install the correct thickness drive pinion position shim on the pinion.

39. NOTE: Always use the same new inner pinion bearing installed when taking the measurement for drive pinion shim selection.

Using the Bearing/Oil Seal Plate and Rear Axle Bearing/Oil Seal Installer and a suitable press, install the pinion bearing.





40. NOTE: Use the thickness of the old drive pinion bearing preload shims as a starting point for setting pinion bearing preload.

Inspect the drive pinion bearing preload shims for damage. Discard them if necessary. New shims are available in the thickness shown in the following chart.






41. If the pinion bearing preload is within specification and the pinion position shim has changed, change the drive pinion bearing preload shims by the same amount.
- The direction arrow pointing toward the pinion flange indicates that by removing the drive pinion position shim, the distance from the centerline of the tubes to the pinion backface increases, giving a plus (+) reading. The drive pinion bearing preload shim pack does not affect the pinion depth setting. However, if the pinion position is changed, the pinion preload will change and may require adjustment to bring the torque-to-rotate within specification. Arrows on the ring gear illustrate the method to increase or decrease backlash and differential bearing preload.





42. Assemble the drive pinion bearing preload shims onto the pinion and install the pinion into the differential housing.

43. Install the outer pinion bearing.

44. Install the pinion flange.

45. Use the Drive Pinion Flange Holding Fixture to prevent the flange from turning while installing the old washer and the locknut.
- Tighten to 339 Nm (250 lb-ft).





46. Using an Nm (lb-in) torque wrench, rotate the pinion. The torque must read as specified.
- To increase the preload, remove drive pinion bearing preload shims. To decrease the preload, add shims.





47. With the drive pinion at the correct preload as determined earlier in this procedure, remove and discard the locknut and the washer. Use the Drive Pinion Flange Holding Fixture to prevent the flange from turning.





48. Using the 2-Jaw Puller, remove the pinion flange.





49. Use rear axle lubricant to lubricate the pinion seal rubber lips.

50. Using a suitable driver, install the pinion seal.
- After installation, verify that the garter spring did not pop out of the seal. If the garter spring popped out, install a new pinion seal.

51. Coat the inside of the pinion flange with a small amount of lubricant.

52. Install the pinion flange.

53. NOTE: Always install a new washer and locknut.

Use the Drive Pinion Flange Holding Fixture to prevent the flange from turning while installing the new washer and locknut.

- Tighten to 339 Nm (250 lb-ft).





54. Position the differential carrier assembly with the master bearings in the axle housing. Install the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge and locate the tip of the Clutch Housing Gauge on a flat surface.





55. NOTE: Repeat this step and the following step until the same reading appears on the indicator each time. This is the differential bearing shim thickness necessary between the differential case and the differential bearing on the differential ring gear side of the differential case.

Force the differential case away from the drive pinion. With force still applied, set the indicator at 0.





56. Force the differential ring gear into mesh with the pinion, to obtain an indicator reading. Record the reading.





57. Remove the Dial Indicator Gauge and Clutch Housing Gauge and the differential case from the differential housing.





58. Remove the master bearings from the differential case.

59. Place one shim, of the necessary thickness, as determined from the previous measurement, on the LH side of the differential case. If additional shimming is necessary, beyond what the hardened differential bearing shim can provide, select and install a different thickness outboard spacer.

60. Using the Differential Carrier Bearing Installer, install the differential bearing on the LH side of the differential case.





61. Determine the correct shim thickness and place it on the differential case hub on the RH side.
- To determine the correct shim thickness, first, subtract the reading of the previous measurement from the total differential case end play reading. Then, add 0.25 mm (0.010 in) to this amount. This is the correct thickness shim to place on the hub. If additional shimming is necessary, beyond what the hardened differential bearing shim can provide, select and install a different thickness outboard spacer.

62. Using the Differential Carrier Bearing Installer and Step Plate, install the differential bearing.

1. Place the Step Plate on the differential bearing to protect it during the installation of the opposite bearing.

2. Using the Differential Carrier Bearing Installer, drive the differential bearing onto the hub.





63. Position the differential bearing cups on the differential bearings.

64. NOTICE: Do not spread the differential housing more than specified or damage to the component may occur.

Using the Differential Carrier Spreader and Dial Indicator Gauge with Holding Fixture, spread the differential housing to the specification. Remove the Dial Indicator.

- Use a rawhide hammer to seat the differential into the differential housing pocket.
- Remove the Differential Carrier Spreader.





65. NOTE: Match the mating letters as noted during disassembly.

Install the 2 bearing caps and 4 bolts, aligning the letters with those on the differential housing.

- Tighten to 108 Nm (80 lb-ft).





66. Confirm the total preload.
- Using a Nm (lb-in) torque wrench, check the torque to rotate the pinion. The reading must be higher than the initial reading (taken without the differential case installed) with new bearings installed as recommended by the following:
- 3.54 and 3.73 = 0.9 Nm (8 lb-in)

- 4.10 and 4.56 = 0.8 Nm (7 lb-in)

- 4.63 and 5.13 = 0.8 Nm (7 lb-in)

- If the total preload is too high, remove an equal amount of differential bearing shims from each differential case hub. If the total preload is too low, add an equal amount of differential bearing shims to each differential case hub.





67. Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, measure the differential ring gear and pinion backlash at 3 equally spaced points.





68. Carry out the tooth contact pattern check to verify the final pinion position is correct.

69. Install the axle shafts. For additional information, refer to Axle Shaft - Semi-Floating Axle Rear Drive Axle/Differential - Dana 60 and 70.

70. NOTE: The driveshaft flange yoke fits tightly on the pinion flange pilot. To make sure that the yoke seats squarely on the flange, tighten the bolts evenly in a cross pattern as shown.

Position the driveshaft flange yoke on the pinion flange with the index marks aligned and install the 4 new bolts.

- Tighten to 112 Nm (83 lb-ft).





71. Fill the axle with the specified type and amount of lubricant. For additional information, refer to Specifications.