front dana 60 rebuild

[darksaga]

I took the diff cover off of my d60 front to check the gear ratio, and when I opened it a oil/water mix came out. Not good.

the internals look fine from what I can see, the ring has no rust but the axles stick on it pretty bad so the bearings are probably shot, Im going to try and rebuild it.

How hard are these to rebuild and for some reason I can't find a complete kit to do it any one have any links?

last time I googled I could not find a complete kit

also I need hubs for it will the hubs off of a dodge or ford d60 work?

[kwmech]

I get my 'kits' at foothill offroad in Auburn they seem to have just about anything I usually need. I think they have a website also.

[BLAZERMAN]

If your looking for bearings and shims try Randys ring and pinion [ 1-800-292-1031 ], if your wanting to rebuild your lower king pin TRW makes a kit and I can get you the number if you want, your upper king pin, poly bushing cup and tension spring can come from any Chevy or dodge dealer.

I'm not sure what you mean by your axles sticking but you may want to check out a few other things before tearing into your case bearings, check wheel bearings, axle u joints and inner spindle bearing first, one of these is more than likely your problem.

If you do pull your axles for any reason clean out the axle tubes before reinstalling them, take a 1-1/2" washer and weld a 3' piece of 3/8" rod to the side of it, insert the washer end thru the axle tube all the way in till you hit the case bearings, [keeping the washer at the top of the tube as you do this] now drop the washer and drag it along the bottom of the tube, you will be shocked at how much scale, dirt and sludge youll get out that would have ended up dozed into your case by the axle upon installation.

Wheel hubs from a Dodge will interchange with the Chevy D60 but they will be externally driven and your lockout selection will be limited to either drive flanges or the Selectro hub which is a very good lockout but expensive. Also the Dodge hub will have 1/2" wheel studs but you can press in Chevy 9/16" studs as they both use the same shoulder diameter. If possible try and get the Chevy hubs as they are internally splined and your lockout selection will be much greater.

[CJM72CHEVY]

Just one little correction. Not all of the Dodge Dana 60 fronts have the external hubs. In fact, I don't know that any do. The Dana 61 used in some Dodges (one-tons I believe) however, does. I had to replace the Dana 60 in my '92 Dodge Cummins when I broke the first one in half (long story). The original axle had internal hubs (as do my dad's '92 and my grandpa's '90 Cummins trucks), but the used axle I got had the external hubs. I was told by knowledgeable people (Inland Truck Parts) that the used axle I got was a Dana 61, used in some Dodge applications, and other than the different lockouts and slightly different internals, it is very similar to the 60 I had 4.10s in it, and it took a different carrier to install the 3.54s out of my old axle. So, when you're Dana 60 hunting in Dodge pickups, be aware that there are similar-appearing axles that are a little different, but would probably still work in a Chevy. And yes, the external hubs are harder to find, but I do believe they are stronger, as well as being easier to lock in. And to the original poster, Danas are a little peculiar compared to most other axles. The preload on the carrier bearings is actually supplied by a tight fit in the case. The holes to either side of the center section are for a special tool that can be used to "spread" the case about .005" to make it easier to remove and install the carrier, and set the pre-load. I've rebuilt a few of them, but it can be rather time-consuming and tedious, particularly if you don't have the special tools for measuring pinion depth and spreading the case. The tools make it easier, but it can still be a job. I took the Dana 61 to ITP for them to put together. I had the gears and a bearing kit (they are available - check any large truck supply outfit - it should have all needed bearings, housing seals, shims, pinion nut and so forth), and with the new carrier I needed, I think it was around $250 to have them install the gears and set it up for me. I'm a professional mechanic, and put a value on my time, so it was money well spent, considering I've spent several hours setting up Danas before, although I am a perfectionist when it comes to that sort of thing. I did, however, install the new axle u-joints and do the rest of the assembly. That's one other thing - don't mess with substandard or discount axle u-joints. The Spicer ones for my axle were about $60 a piece, but well worth it compared to the quality of some Brand-X u-joints.

[Rod]

Lots of links to articles and lots to read here at this site.
http://www.pirate4x4.com/tech/billav...ont/index.html

[BLAZERMAN]

Thanks for the link Rod, lots of good info on there and even some pics of the dodge D-60 external drive hubs that dont exist.

[CJM72CHEVY]

Is that comment in response to my post? If so, I suggest you go back and re-read it. I didn't say that they don't exist, but that I've never seen a Dana 60 with them. Every Dodge front axle with the external lockouts that I've seen has been the very-similar Dana 61. Since the hubs are interchangeable between the two axles (60 and 61), it's easy to install external lock-outs on a 60, or internal hubs on a 61. My info comes from having one of each apart, owning a '92 Dodge Cummins with a Dana 60 that was replaced with a 61, in addition to the half-dozen other Dodge Cummins trucks family members own. We also have a 1-ton Dodge service truck here with external hubs, and it also has a Dana 61 in it. How many do you own, and would you know how to differentiate between a Dana 60 and 61? I didn't, until I had ITP run the numbers from the replacement axle. This is one subject that I actually might know something about, and maybe more than you, since you apparently weren't aware the 61 even exists.

[darksaga]

Originally posted by BLAZERMAN


I'm not sure what you mean by your axles sticking but you may want to check out a few other things before tearing into your case bearings, check wheel bearings, axle u joints and inner spindle bearing first, one of these is more than likely your problem.

when I turn the yoke the shafts stick, also when I turn the shafts they come to a point to where I can't turn them anymore (easily)

as for the hubs summit has some on sale so I may pick some up and add them to the parts pile for later

[BLAZERMAN]

I dont claim to be an expert on the dana 60, I have rebuilt a few of them including the the one in my 69 that is a chevy military version with 1980 dodge external hubs. I have 2 more chevy versions and a dodge unit for parts. I dont know much about the D-61 other than it was designed with a different pinion centerline in ths case to be able to run a 3.08 gear ratio, dana 60s can only go as high as a 3.54 and I believe the D-61 is the same as the 60 in every other way except the pinion center line, carrier and gears. Most all the dodge 60s I have seen have been in the 70s to early 80s and have had the external hubs and all had lower gears so I am sure they were 60s. I think the 61s were only a late model thing,

[CJM72CHEVY]

I'm pretty sure we're both right. All of the 60 fronts I've been exposed to have been in the '90- and up Dodge Cummins trucks. I've also been around a few Chevy 1-tons, but those also had the internal hubs. You're correct about the different pinion centerline in the 61, and I think all other parts interchange. That's probably why I had to buy a different carrier to run the 3.54s in the 61.

[ckhd]

All I know about the debate is: I have a '89 Dodge Cummins 3/4 ton with a D61 front, 3.54 gears and manual locking hubs. Wish it was a D60 because there seems to be more options for locking diffs...