Installing Axle after Posi Rebuild? - The 1947 - Present Chevrolet & GMC Truck Message Board Network

HeavyK20 · 06-29-2005, 08:15 AM

I have a rebuilt Dana 60 posi rear that I am trying to intall axles into. One side went in fine but the posi side stops about 1" short of going all the way in. I'm assuming that there are 2 sets of splines that the axle has to go through and the splines are not lined up. I can't get the posi to slip enough to let the splines line up. Any suggestions?

Americanrider · 06-29-2005, 02:23 PM

I've only played with Eatons & Front Danas but there is a LONG SIDE and a SHORT SIDE to the axle shafts of the Eatons (unsure about Dana 60 rears). Are you sure you don't have them switched?

HeavyK20 · 06-29-2005, 03:42 PM

I checked and Both axles are the same length in a 60 rear.
A guy I work with gave me a good idea that I am going to try tonight. He told me to weld a nut on the flange of an old axle (which I happen to have) and use an impact wrench to turn the first spline until the axle pushes all the way in.

HeavyK20 · 06-30-2005, 09:05 AM

The impact gun worked. I welded a large nut onto the axle and used a 3/4" impact wrench to turn the axle. The axle dropped right in after about 3 strokes of the impact.

Americanrider · 06-30-2005, 02:11 PM

Cool... file that away under the heading of: How to make life easier

**JIMs70GMC** · 07-01-2005, 06:46 AM

Eric, you have any pics? did you do the rebuild yourself? Any literature? I have a power-lock in my dana60(GMC) and figure after 35 years it could use some TLC.

HeavyK20 · 07-01-2005, 08:18 AM

I don't have any pic's, I had an axle shop do the rebuild. I was not real happy with the workmanship they provided. After I got it back from the rebuilder I opened the differential up and found that they didn't do a very good job of cleaning the housing. So I ended up taking everthing back apart to clean it.

I had the axle shop do the work because I changed the ratio and didn't have the tools or experience to do the job. If your ring and pinion and bearings are Ok, rebuilding the posi is pretty easy. The posi disassembly does not change the rear end set up, you can pull the axles and drop the differential out. The differential carrier splits in half service the posi clutch pack.

There is a lot of good tech information at www.pirate4x4.com

**JIMs70GMC** · 07-01-2005, 09:00 AM

what ratio did you go with?

HeavyK20 · 07-01-2005, 09:28 AM

I went with 3.73

**JIMs70GMC** · 07-01-2005, 09:51 AM

Did you have to change the carrier or did you buy a new posi?

HeavyK20 · 07-01-2005, 10:00 AM

I went from 4.10 to 3.73, I can't remember for sure but I think a 60 uses the same carrier for 4.10 and 3.73. So, I'm assuming that they reused the carrier and just replaced the posi clutch pack.

06-29-2005, 08:15 AM	#1
HeavyK20 Registered User Join Date: Dec 2001 Location: New Richmond, WI Posts: 547	Installing Axle after Posi Rebuild? I have a rebuilt Dana 60 posi rear that I am trying to intall axles into. One side went in fine but the posi side stops about 1" short of going all the way in. I'm assuming that there are 2 sets of splines that the axle has to go through and the splines are not lined up. I can't get the posi to slip enough to let the splines line up. Any suggestions? __________________ Eric 1969 K20, 465/205 package Last edited by HeavyK20; 06-29-2005 at 08:17 AM.

06-29-2005, 03:42 PM	#3
HeavyK20 Registered User Join Date: Dec 2001 Location: New Richmond, WI Posts: 547	I checked and Both axles are the same length in a 60 rear. A guy I work with gave me a good idea that I am going to try tonight. He told me to weld a nut on the flange of an old axle (which I happen to have) and use an impact wrench to turn the first spline until the axle pushes all the way in. __________________ Eric 1969 K20, 465/205 package

06-30-2005, 09:05 AM	#4
HeavyK20 Registered User Join Date: Dec 2001 Location: New Richmond, WI Posts: 547	The impact gun worked. I welded a large nut onto the axle and used a 3/4" impact wrench to turn the axle. The axle dropped right in after about 3 strokes of the impact. __________________ Eric 1969 K20, 465/205 package

07-01-2005, 06:46 AM	#6
JIMs70GMC user # 2756 Join Date: Jun 2001 Location: Chesapeake, Virginia Posts: 4,612	Eric, you have any pics? did you do the rebuild yourself? Any literature? I have a power-lock in my dana60(GMC) and figure after 35 years it could use some TLC. __________________ 1970 K25, 8' stepside bed 350/465/205 44 up front, 60 in the rear 4.10s rolling on 33" Dunlop MTs 1986 K5, 350/465/208 Dana 60/14 bolt from a cucv 36" Super Swampers TSL/SX 1983 K20 w/ CUCV axles, 350/700R4/208 sitting on 37" Goodyears 1986 M1031 6.2 diesel, TH400/NP205 locker in the rear and a LS in the front, all stock for now..... 1986 K30, 350/400/205 dana 60 and 14 bolt. I kept the drivetrain. Body/bad and chassis are gone. 1981 K30, 350/465/205 dana 60 and dually 14 bolt. Has a G80, and a flat bed. Going to replace the flat bed. 1985 K20, 350/400/208 10 bolt and SF 14 bolt. I wonder where I can find some 1 tons. Hmmmmm

07-01-2005, 08:18 AM	#7
HeavyK20 Registered User Join Date: Dec 2001 Location: New Richmond, WI Posts: 547	I don't have any pic's, I had an axle shop do the rebuild. I was not real happy with the workmanship they provided. After I got it back from the rebuilder I opened the differential up and found that they didn't do a very good job of cleaning the housing. So I ended up taking everthing back apart to clean it. I had the axle shop do the work because I changed the ratio and didn't have the tools or experience to do the job. If your ring and pinion and bearings are Ok, rebuilding the posi is pretty easy. The posi disassembly does not change the rear end set up, you can pull the axles and drop the differential out. The differential carrier splits in half service the posi clutch pack. There is a lot of good tech information at www.pirate4x4.com __________________ Eric 1969 K20, 465/205 package Last edited by HeavyK20; 07-01-2005 at 08:30 AM.

06-29-2005, 02:23 PM	#2
Americanrider Registered User Join Date: Dec 2004 Location: NW, WA. Posts: 1,421	I've only played with Eatons & Front Danas but there is a LONG SIDE and a SHORT SIDE to the axle shafts of the Eatons (unsure about Dana 60 rears). Are you sure you don't have them switched?

06-30-2005, 02:11 PM	#5
Americanrider Registered User Join Date: Dec 2004 Location: NW, WA. Posts: 1,421	Cool... file that away under the heading of: How to make life easier

07-01-2005, 09:00 AM	#8
JIMs70GMC user # 2756 Join Date: Jun 2001 Location: Chesapeake, Virginia Posts: 4,612	what ratio did you go with? __________________ 1970 K25, 8' stepside bed 350/465/205 44 up front, 60 in the rear 4.10s rolling on 33" Dunlop MTs 1986 K5, 350/465/208 Dana 60/14 bolt from a cucv 36" Super Swampers TSL/SX 1983 K20 w/ CUCV axles, 350/700R4/208 sitting on 37" Goodyears 1986 M1031 6.2 diesel, TH400/NP205 locker in the rear and a LS in the front, all stock for now..... 1986 K30, 350/400/205 dana 60 and 14 bolt. I kept the drivetrain. Body/bad and chassis are gone. 1981 K30, 350/465/205 dana 60 and dually 14 bolt. Has a G80, and a flat bed. Going to replace the flat bed. 1985 K20, 350/400/208 10 bolt and SF 14 bolt. I wonder where I can find some 1 tons. Hmmmmm

07-01-2005, 09:28 AM	#9
HeavyK20 Registered User Join Date: Dec 2001 Location: New Richmond, WI Posts: 547	I went with 3.73 __________________ Eric 1969 K20, 465/205 package

07-01-2005, 09:51 AM	#10
JIMs70GMC user # 2756 Join Date: Jun 2001 Location: Chesapeake, Virginia Posts: 4,612	Did you have to change the carrier or did you buy a new posi? __________________ 1970 K25, 8' stepside bed 350/465/205 44 up front, 60 in the rear 4.10s rolling on 33" Dunlop MTs 1986 K5, 350/465/208 Dana 60/14 bolt from a cucv 36" Super Swampers TSL/SX 1983 K20 w/ CUCV axles, 350/700R4/208 sitting on 37" Goodyears 1986 M1031 6.2 diesel, TH400/NP205 locker in the rear and a LS in the front, all stock for now..... 1986 K30, 350/400/205 dana 60 and 14 bolt. I kept the drivetrain. Body/bad and chassis are gone. 1981 K30, 350/465/205 dana 60 and dually 14 bolt. Has a G80, and a flat bed. Going to replace the flat bed. 1985 K20, 350/400/208 10 bolt and SF 14 bolt. I wonder where I can find some 1 tons. Hmmmmm

07-01-2005, 10:00 AM	#11
HeavyK20 Registered User Join Date: Dec 2001 Location: New Richmond, WI Posts: 547	I went from 4.10 to 3.73, I can't remember for sure but I think a 60 uses the same carrier for 4.10 and 3.73. So, I'm assuming that they reused the carrier and just replaced the posi clutch pack. __________________ Eric 1969 K20, 465/205 package Last edited by HeavyK20; 07-01-2005 at 10:01 AM.



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