Dana 60 gear swap

[Jonathans55]

Ok so the truck is a 55 chevy 3600 with a Dana 60 running 4.11. I have a 350sb with a th350 transmission. I want to at least go 60 to 70 without redlining almost like I basically am now. First question: which gear should I use. Secondly how ridiculously difficult is this job. I was quoted 900 to 1000 bucks for this and I'm definitely not spending that. Hell I built my engine from the ground up no way I'm paying that for someone to do it. I just like to know what I'm getting into since this will be my first time ever opening a rear end. It's like Christmas right? Lol. Also if anyone can point me in the direction for the parts Id need that would rock.

[bomber66]

I'd put a 700R4 Tranny in it and call it good, burn the tires and be able to hit the interstate.

[eagleuh1]

I have Dana 60 with 3.54 gears in my 68 Long Bed 3/4 ton. I like it. Tows good too. I have a 5.3, 4L60E tranny in it though. Originally came with Dana 60 with 4.56 gears and 327, TH400. Not good for speed or milage, but sure pulled good. Good luck with the rebuild. Just make sure the carrier with 4.11's can carry the better gears your going for. Theres a split somewhere where theres a different carrier required. Jim

[yossarian19]

IIRC all the Dana axles use shims to adjust backlash / pinion depth.
A word to the wise is to use a brake or piston cylinder hone on a cordless drill with the old bearings & open them up until they can go on / off the carrier and pinion by hand.
This way you can go back and forth a few times making sure you have everything set up correctly before you need to press bearings on.
Ideally, you'd buy two new sets of bearings from the same manufacturer and hone out one of the new sets. Might be worth using a micrometer and measuring the difference in thickness between the old ones and the new set, though, if you aren't going to buy a double set of bearings.

As for ratio...
Depends a little bit on your tire size. 3.55's are probably a safe bet but I would google search "tire size gear ratio rpm" and find a calculator online. I can say that my old Jeep Cherokee with a 29" tire and 3.55s spun about 3K RPM at 70 mph while in third gear (1:1 trans ratio).

[mr48chev]

I'm not sure what year rear end you have under the truck but I picked up the 3.54 posi rear for my 71 GMC for 150 bucks a couple of years ago complete. Finding a complete rear axle with the right gears might be a lot easier than trying to swap ring and pinion when you aren't set up to swap that particular ring and pinion.

[1project2many]

Ring & pinion is expensive. Labor to properly disassemble, clean, and set up can be 4 hrs to 8 hrs with clean, running axle on the low end. Make a mistake and chew up parts and repair cost is usually more than cost of pro install.

You'll need the gears and a shim set at a minimum, with complete install kit being preferred. Spare bearings can help because, as mentioned above, you need to use trial and error method to determine which shims are appropriate. Make sure to clean, clean, clean the housing. Then clean it again. Nothing will ruin an install faster than leaving metal in the axle housing. Dial indicator is a must. Calipers or micrometer is nearly impossible to do without. Checking pinion preload requires special tools or someone who already has a feel for it. Lotsa pictures of gear patterns will help when setting up gears. Check pattern first, take pictures, and measure clearances. This can help you decide what's OK if new parts aren't quite up to specs (it happens!). Carefully not positioning and placement of parts, order of parts, etc. Take notes. Be sure to measure all shims that are removed in order to get correct starting point. Note that pinion depth shim under bearing cone can be replaced with pinion depth shims under cup. Ultimately the job can be done at home but really best to find someone with experience to help and check work. Post updates if you do it here and don't be afraid to ask more questions.

Dana 70 is close to 60.
http://www.billavista.com/tech/pdf_i...Model%2070.pdf

Note about using cup or cone pinion shims
http://www.billavista.com/tech/pdf_i...xl-Tec-12).pdf

Military manual, shows Dana repairs of 60/70. Use sections for M1028A2.
http://www.billavista.com/tech/pdf_i...on%20Axles.pdf

And the awesome reference page these can all be found at:
http://www.billavista.com/tech/pdf_i...ars/index.html

[mr48chev]

I'll be honest, even with the skills I have and the equipment I have I personally won't attempt to swap gears in one of those and probably would take the axle to a specialist to have anything beyond changing wheel bearings. The reasons are exactly what 1project2many listed in his post. It not only takes special tools it takes quite a bit of knowledge and patience.

[lower50's]

The carrier split for a dana 60 is 4:11 and down so you will be fine with what you have. If you built your motor you should be able to do the gears, just takes time. I put 4:56 gears in my Jeep Dana 44, never done gears before, no prob for 10 years. If you want a posi I would go with Eaton detroit truetrac, very good posi no clutches to wear out. Here is a gear calculator I use all the time, just enter in info and use the Dana 20 T case 1:1 high range. Then go to bottom of page and that is high range speed and rpm. Hope that helps
http://www.grimmjeeper.com/gears.html