Section 05-02D: Axle, Rear, Dana | 1996 F-Super Duty Workshop Manual |
| Description | Tool Number |
|---|---|
| Companion Flange Holding Tool | T57T-4851-B |
| Pinion Shaft Thread Protector | T85T-4209-AH |
| Bearing Cup Puller | T77F-1102-A |
| Impact Slide Hammer | T50T-100-A |
| Outer Pinion Bearing Cup Remover | T88T-4628-A |
Differential Case Removal
If necessary, due to size limitations, remove the rear axle (4001) from the vehicle. Refer to Axle, Rear, Removal and Installation in this section.
Remove axle housing cover plate screws and axle housing cover (4033). Tip carrier to allow lube to drain completely. Clean the cover face of the carrier, making sure it is free from any nicks. Remove old RTV gasket material.
CAUTION: Before removing differential case (4204) and ring gear, pull axle shafts (4234) out far enough for clearance to remove differential (4026). Refer to Section 05-02E.
NOTE: Mating letters are stamped on rear axle bearing retaining caps and carrier. Letters are in vertical and horizontal positions. Note the positions of letters before removal. Matching letters is important at time of assembly.
Remove rear axle bearing retaining caps.
Place Differential Housing Spreader TOOL-4000-E or equivalent on the rear axle housing (4010). Install Dial Indicator/Magnetic Base D78P-4201-B or equivalent on the rear axle housing. Do not spread rear axle housing more than 0.38mm (0.015 inch).
NOTE: Use caution to avoid damage to ring gear.
Pry differential case from carrier with two pry bars. After differential case has been removed, remove spreader.
Mark or tag differential bearing cups (4222) indicating from which side they were removed.
| Item | Part Number | Description |
|---|---|---|
| 1 | TOOL-4000-E | Differential Housing Spreader Tool |
| 2 | — | Ring Gear (Part of 4209) |
| 3 | 4K067 | Right-Hand Spacer |
| 4 | 4K067 | Left-Hand Spacer |
| 5 | — | Pry Bars |
The rear axle has spacers installed outboard of each differential bearing cup. Remove both spacers and tag each indicating the side each was removed from. Inspect both spacers for damage, bent or grooved conditions. Replace if required.
Differential Case Disassembly
NOTE: Differential bearing shims (4067) are available in thicknesses of .08, .13, .25 and .76mm (.003, .005, .010 and .030 inch).
Remove differential bearings with Pinion and Carrier Bearing Puller D81L-4220-A or equivalent. Place the tool in a vise when removing bearing. Wire differential bearing shims, differential bearing cup, bearing cone, and outboard spacer together. Identify from which side they were removed (ring gear side or opposite side). If differential bearing shims are damaged, replace with new ones.
Reposition differential case in puller and remove other bearing cone as described above. Replace bearings whenever removed from the carrier.
Place a few shop towels over the vise to prevent the teeth of ring gears from being nicked. Place differential case in vise.
CAUTION: Use care to not damage speed sensor ring when removing ring gear. If the speed sensor ring is removed, it must be replaced with a new one.
NOTE: Whenever removing the ring gear bolts, always replace with new bolts upon assembly. Use grade 9 bolts for service replacement for all Dana rear axles.
Remove bolts on ring gears. Leave four bolts loosely assembled 90 degrees apart.
Tap each bolt head alternately with a rawhide hammer to loosen the ring gear. Remove bolts and ring gear.
If required, remove the speed sensor ring with a soft-faced hammer. Discard the speed sensor ring.
Replace differential case in vise. Use a small drift to drive out differential pinion shaft lock pin (4241) which secures the differential pinion shaft (4211).
Remove differential pinion shaft with drift as shown.
To remove differential side gears (4236) and differential pinion gears (4215) rotate the differential side gears. The differential pinion gears will turn to the opening of the differential case.
Remove differential pinion gears and differential pinion thrust washers (4230) behind the differential pinion gears.
Lift out differential side gears and differential side gear thrust washers (4228).
Inspect all parts, including the machined surfaces of the differential case itself. If excessive wear is visible on all parts, the complete differential should be replaced. If any one of the gears is to be replaced, replace as a set.
Drive Pinion Removal
WARNING: HANDLE PINION GEAR CAREFULLY TO PREVENT INJURY.
On the spline end of the pinion, there are pinion shims. These pinion shims may stick to the pinion or bearing or even fall out. These pinion shims are to be collected and kept together for reassembly. Try not to damage pinion shims. If drive pinion shims are damaged, replace with new ones. Refer to Pinion Shims chart under Pinion Position Shim Selection in this section.
Drive Pinion Assembly
| Item | Part Number | Description |
|---|---|---|
| 1 | — | Drive Pinion (Part of 4209) |
| 2 | 4663 | Drive Pinion Bearing Adjustment Shim |
| 3 | 4616 | Differential Drive Pinion Bearing Cup, Outer |
| 4 | 4670 | Rear Axle Drive Pinion Shaft Oil Slinger |
| 5 | 4859 | Drive Pinion Oil Seal Deflector |
| 6 | 1124 | Rear Wheel Pinion Nut Locking Washer |
| 7 | 390313-S100 | Pinion Nut |
| 8 | 4851 | Rear Axle Universal Joint Flange |
| 9 | 4676 | Rear Axle Drive Pinion Seal |
| 10 | 4630 | Differential Pinion Bearing |
CAUTION: The pinion shim assembly sequence must be followed. If sequence is not followed and components are improperly assembled, it may cause unit failure.
NOTE: Pinion nut requires 597-677 Nm (440-500 lb-ft) of torque to remove.
Turn nose of carrier in a horizontal position and remove pinion nut. Hold pinion flange with Companion Flange Holding Tool T57T-4851-B and remove pinion nut and drive pinion nut locking washer.
Remove rear axle universal joint flange (4851) with 2-Jaw Puller Tool D80L-1002-L or equivalent. Replace pinion seal if rear axle universal joint flange shows signs of wear.
Remove pinion by tapping with a rawhide hammer and Pinion Shaft Thread Protector T85T-4209-AH. Catch the pinion with your hand to prevent from falling and being damaged.
Pinion Bearing Cup Removal
Pull out rear axle drive pinion seal (4676) with Bearing Cup Puller (Oil Seal Replacer) T77F-1102-A, and Impact Slide Hammer T50T-100-A. Discard rear axle drive pinion seal. REPLACE WITH NEW ONE AT TIME OF ASSEMBLY. Remove differential pinion bearing (4630) and drive pinion shaft bearing thrust washer.
CAUTION: Do not nick bore of carrier.
NOTE: The front and rear section of carrier may vary in pinion bore depth due to the need for either a baffle or oil slinger or both. The baffle serves the same purpose as a dam, to maintain pinion bearings with lubricant. The oil slinger serves the purpose of assisting the lube to flow up through the oil channels to lubricate the pinion bearings. If used, they are part of the pinion setting adjustment.
Turn nose of carrier down. Remove outer differential bearing cup with Driver Handle D81L-4000-A or equivalent and the Outer Pinion Bearing Cup Remover T88T-4628-A as shown in the following illustration.
NOTE: Drive pinion bearing adjustment shims (4663) are located between the differential drive pinion bearing cup (4616) and bore of carrier and may also include an oil baffle. If pinion shims and baffles are bent or nicked, replace at time of assembly. Wire pinion shims may stack together; if so, measure stacks. If stack has to be replaced, replace with pinion shim of same thickness.
Remove the inner differential bearing cup with Driver Handle D81L-4000-A or equivalent and Pinion Bearing Cup Replacer D81T-4616-A or equivalent as shown in the following illustration.
| Item | Part Number | Description |
|---|---|---|
| 1 | D81T-4616-A | Pinion Bearing Cup Replacer (Inner) |
| 2 | T88T-4628-A | Outer Pinion Bearing Cup Remover |
| 3 | D81L-4000-A | Driver Handle |
| 4 | 4616 | Differential Drive Pinion Bearing Cup |
NOTE: Both baffle and rear axle drive pinion shaft oil slinger (4670) are part of the pinion shims and are to be kept intact for assembly.
Remove differential pinion bearing from pinion with Pinion and Carrier Bearing Puller D81L-4220-A or equivalent.
