Re: Spring Swap Thread - 1963 K15
 

Hey JWALT,
The holes that lined up for me were the center hole of the DIY bracket and one of the top rivet holes for the cross member brace on the inside of the frame. Even though the holes "kinda" lined up, I did have to wallow them out a little.

Whats a little strange though is that on this last go round on my truck (the engine swap), I pulled the front sheetmetal off. My core support was rotten at the frame / mounting area so I picked up a new - used one off of a later Burb (thanks Randy!). When I went to install the core support, it seemed as though the mounts were farther apart than on the original. I really had to wedge the long support bolts in and then crank down the nuts.

I just chalked it up to tolerances being a little loose on the old truck.

One other thing that it could be. I do know that mine was in a wreck on the passenger side at one time. I don't think that the frame is affected but Im pretty sure that the firewall on that side is pushed in a little. Since the inner fender is supported by the firewall and more or less sets the distance for cab to core support, there could be a discrepancy there? You might want to take a few measurements (core support to cab on both sides)?

Re: Spring Swap Thread - 1963 K15
 

Thank you for an awesome write up on this process. And thanks for taking the time to answer everyone's questions. When are you going to show the us something on the new engine and tune that you have done since this post? Or did I miss it? Are you in trouble with your wife all the time like I am over my truck? lol

Re: Spring Swap Thread - 1963 K15
 

Anytime. I really like how its worked out. I was able to get her out of the garage yesterday under her own power and down to the exhaust shop.

I have no idea how to post a link but its in the engine and drivetrain section under "7.4 L29 Build for '63 K15 with NV4500" or something like that.

Re: Spring Swap Thread - 1963 K15
 

Well since I got her Bug back in the garage yesterday, things have been pretty cool at the house. LOL. She was even helping install carpet, hood and fenders just to get it out of the garage. It was pretty funny.

Re: Spring Swap Thread - 1963 K15
 

Subscribing for future reference :)

Re: Spring Swap Thread - 1963 K15
 

Bringing it back from a short pause. An update, a repair, a little maintenance and as usual, a bunch of questions (and of course pics) coming soon.

Re: Spring Swap Thread - 1963 K15
 

Finally getting back to finish up a few items that were bothering me from the last go round. So far Ive logged at around 7 - 8 thousand miles on the new suspension. Unloaded, its a real comfortable ride, articulates well stops better than before and is an all around improvement for my usage.

There are however a few shortcomings which I was hoping to address before our summer camping trip in 3 weeks, namely;

Ball joints- since I first swapped the front axle onto the truck (7 years ago?) I knew the ball joints on the Dana 44 were marginal. There was a little play evident in that I could rock the wheels top to bottom maybe 1/4". Bearings were repacked and adjusted so I knew it wasn't that.

Front spring pack stiffness - although the ride is super smooth now with the 52s, it has become clear that I needed something a little firmer. The 5/16 - 5 leaf pack has always been a little looser than I like for my taste. I was thinking that maybe going to a 6 leaf pack of the same thickness. Then there was also the issue of a possible hairline crack in the 2nd from the bottom spring on the drivers side. Couldn't tell at the time if it was a scratch or what but back in February, the boy and I were driving and heard what sounded like a 5/8 or 3/4 wrench either fall out of the truck or get kicked up by the wheel. We stopped in traffic, looked around and didn't see anything. Well, lets just say that I found out yesterday what the sound was.

Aside from the ball joints and springs, I was going to do inner and outer bearings and seals, new calipers, vent the axle, install some Warn Premium hubs, change the gear oil and giver her a coat of paint to match the rest of the underside.

Re: Spring Swap Thread - 1963 K15
 

The first surprise was the missing 6 - 7" of the leaf spring:lol:

I started disassembling the axle starting on the passenger side. The amount I could rock the wheel top to bottom had grown to near 1" by now. By the time the knuckle was off, it was apparent that the ball joints were hosed. And this was the good side.

Got to the driver's side, everything still going smooth. On this side, the wheel could be rocked 1-1/4 to 1-1/2". Before anyone says anything, yeah, I let this go way too long, I know. been too dam busy trying to get through probation at work to pay attention to the vehicles. Anyway, I got to the knuckle removal and it came off without incident. Popped it into the parts cleaner and as I was moving it, the upper ball joint pulled out. CRAP!

In comparing the two knuckles I noticed that the upper part of the driver's knuckle appeared bent and the bore for the joint wallered out. Possibly a bad press job? The left knuckle is the pass. side. The right is the dr. side. Notice how the joint doesn't sit flush with the bent flat top? And yes, the joint goes in and out easily by hand.

Looks like Im on the hunt for a new knuckle now as well.

Re: Spring Swap Thread - 1963 K15
 

Why does it always seems that when everything going great until you get to the second side, I feel for ya.

Re: Spring Swap Thread - 1963 K15
 

I have no idea why it always goes like that :lol:. I had the driver's side almost all the way stripped down for a day already. Was taking my time, feeling real good about the idea of driving straight down the road soon. Took me a few minutes to process what happened when that joint fell out. Although I don't think it can "pop out" while driving, it certainly wasnt the way it should have been and I do consider myself lucky that nothing happened while I was moving.

Just trying to decide if I want to fix this axle, get another 44 or rewrite the script and get onto a Dana 60 now. Kind of a crossroads moment for me. Craigslist here I come!

Re: Spring Swap Thread - 1963 K15
 

Re: Spring Swap Thread - 1963 K15
 

Lol. You're Killin me Steve!

FWIW, I found a driver's side knuck on EvilBay for just under 100 shipped. I've been looking at 60s since Friday and all I can say is HOLY CRAP THEYRE EXPENSIVE! I may still go that way if I can find a deal on one. Right now though they start at 1600 to 2500.

As always I have Cadillac taste on a Chevette budget!

Re: Spring Swap Thread - 1963 K15
 

Holy crap, they have gone up! $1,000 for a ready to go runner was what I was used to. At that price a guy has to really consider their needs.

44444444

Re: Spring Swap Thread - 1963 K15
 

RETREAT!!! I think the 44 will be fine for what I'm gonna be doing and with the prices of the 60, that little 44 that only needs a couple hundred in parts is looking better all the time.

Last 60 I bought was for the '76 CC Dually I converted to 4wd 18 years ago. Think I paid 700 for it. Yes times have changed!

Re: Spring Swap Thread - 1963 K15
 

WOW! 1600 to 2500 for a 60?.......should be dang near able to buy a whole K30 for not much more than that.

Yeah the last single wheel Dodge 60 I bought I think I paid 900-1000.

Re: Spring Swap Thread - 1963 K15
 

I was thinking the same thing Captain and had actually started entertaining the thought of just that. Buying another truck! Haha. My Wife would have killed me!

Not sure if its "California" pricing but I wouldn't be surprised. I did see some Rockwells that looked kind of reasonable, but that's a whole 'nother ball of string. I'd have to also buy a forklift as well to move those things around!

I will be happy enough to just have a front axle that works when I need it. Hoping to wrap up the crossmember to driveshaft clearance issue and also get the 205's shift linkage installed in this go 'round. Pics coming soon.

I think the new / used knuckle will do the trick. Add a set of USA Moog ball joints, Spicer U joints and seals, USA Raybestos calipers and a fresh coat of paint and she should be good to go back in. I was going to do the bearings as well but opened the box of National bearings that I had bought to find that they are all made in China :(. So I took a little closer look at the Koyo (Japan) bearings that were in there and they (and the races) looked brand new. Think Ill just repack those and save a few $$$.

As far as the cracked spring, Ill probably take the 2 bottom leaves off of the original front set (45") that came with the truck and replace the 2 lowest leaves on the 52" pack. It might stiffen up the ride the amount Im looking for. Its all trial and error at this point. Wish I could afford a new set of springs but sure am thankful for the hoarding gene that I have right now!

Re: Spring Swap Thread - 1963 K15
 

The last D60 that I bought was only 400 and that was with in the last 5 yrs as I still have it.

Re: Spring Swap Thread - 1963 K15
 

There's a '68-72 3/4ton 2wd here being parted that has a Dana 60 rear... I've already got a full set of 6-bolt wheels, and an original GMC Dana44 rear with 3.55 and rebuildable posi... I'm reallllllly trying to ignore it... I'd be into the Dana for whatever the purchase price is, plus the rebuild kit, plus 3.55 gears (probably) and a new posi unit, AND a full set of 6-lug wheels.
I could get a Dana 60 for free, and it'd still cost me a grand.
I'm figuring that for the light wheeling I'll be doing (easy trail rides, hunting and driving through fields, etc., no rock-crawling), with original pizza-cutter wheels and tires, the 44s will be up to it.

Re: Spring Swap Thread - 1963 K15
 

It seems they are appreciating much like the real estate here. That said, would you take 500 for your 60 ;)

Re: Spring Swap Thread - 1963 K15
 

Like most people on here I'm a hoarder

Re: Spring Swap Thread - 1963 K15
 

Me too. One day, Ill use all of the treasures that I have stashed under the house.

Re: Spring Swap Thread - 1963 K15
 

Here's a few pics to update the progress.

So I knew that I had a broken leaf spring end on the driver's side pack and that I needed ball joints. With this in mind, I got the parts and set to it.

Re: Spring Swap Thread - 1963 K15
 

My first speed bump was the bent driver's side knuckle that wouldn't hold the upper ball joint. I purchased a used one on evil bay, cleaned, painted it an pressed in all of the ball joints. I installed the knuckles using the 30# torque to bottom joint, 50# on the preload sleeve on top, 100# on top joint castle nut followed by 70# on the lower joint to finish.

Re: Spring Swap Thread - 1963 K15
 

oooooh...

Re: Spring Swap Thread - 1963 K15
 

The inner axle seals didn't leak as far as I knew but since I had it down this far, I figured if I put it back together without changing them, they'd start leaking. So I changed them.

I will say, I did have a mental block towards pulling the carrier. Ive never pulled one out for fear of messing it up. It came out pretty easy. It looks as though someone sprayed it with epoxy or paint at some point. Guess some people have a bigger OCD than I do for painting things.

I will say the axle tube were NASTY! Coated with a mixture of sand, water, gear oil and dirt, it took a couple of hours to clean them out with a 3/4" pipe and rags.