Clunk-clunk Dana 60 front, kingpins?

[Americanrider]

I have this yet unidentified Clunking noise coming from the front D60 under my 85. When sitting still and turning the wheel and changing direction in parking lots at slow speed is when I hear it. My first guess is Kingpins gone bad. Anyone have a method for checking the D60 Kingpins without tearing into the axle? It seems to be coming more from the right side than the left. This is in 2wd drive mode, front axle not engaged.

Also noted is hairline heat stress cracks forming on the rotors. Due in part to whimpy rear brakes (those I fixed already) How long can I still run the rotors without worry or should I just change them out now?

[vtblazer]

I'd check the steering linkages before I'd blame the D60.

Tie rod ends, idler arm, bolts on the steering box...etc.

[Burt4x4]

Jack up the front and then see if you can 'rock' the tire from top to bottom, just like checking ball joints. If your tire rocks then you KPins are worn/loose. I have heard of people putting big washers in there to stiffin the spring but I have never done that....

[powerdriver 1958]

Brakes are a Safety Issue,Don't take chances!!!!!!!!!!

[BLAZERMAN]

Originally Posted by Americanrider

I have this yet unidentified Clunking noise coming from the front D60 under my 85. When sitting still and turning the wheel and changing direction in parking lots at slow speed is when I hear it. My first guess is Kingpins gone bad. Anyone have a method for checking the D60 Kingpins without tearing into the axle? It seems to be coming more from the right side than the left. This is in 2wd drive mode, front axle not engaged.

Also noted is hairline heat stress cracks forming on the rotors. Due in part to whimpy rear brakes (those I fixed already) How long can I still run the rotors without worry or should I just change them out now?

Do yourself a favor and try this first, about 20 bucks and an hours worth of work, a good chance it will cure your problems.
http://offroaddesign.com/catalog/D60...ng-bushing.htm

[Americanrider]

I have the front tore down right now and I'm getting new rotors pressed on the hubs. All the bearings look great so I'm going with new seals and a re-pack. The upper Kingpin replacement look easy, what about the lowers, are they hard to replace?

[vtblazer]

Originally Posted by Americanrider

I have the front tore down right now and I'm getting new rotors pressed on the hubs. All the bearings look great so I'm going with new seals and a re-pack. The upper Kingpin replacement look easy, what about the lowers, are they hard to replace?

Nope.
4 bolts, tap on the cover and drop it out.