"Bulletproof"

Dana 60 Build Up

By: Tim Fryer "Shaker"
Yeah as most of you know the "Famous" Dana 60 is the "Ultimate" front axle to have in your 4x4. So as I'm doing the Blazer project I figured I might as well start collecting parts for one. I know as soon as I get the "Doubler" installed it's gonna take it's toll on the Dana 44. After looking all around my area for a decent priced Dana 60 front I came to the conclusion that I would have to build it piece by piece. I look at it as being easier on the wallet in the long run (or so it seems-lol). Anyone who has put one of these together knows that Dana 60 = $$$ for parts. These axles are getting harder to get your hands on in my area (VA.) without having to sacrafice your arm paying for it. I started looking around for parts on Ebay and asking 4x4 buds who had any parts "laying" around. I ended up buying parts from 6 states in the US-LOL. I did some research on the "inner" axles and I ordered the Large shafts (Spicer Part # 660182-2 & 660182-1) they are 35 spline with a whopping 1.71 in diameter (YEAH!). Some of the Dana 60 axles have a "neck down" in them that makes them weaker in those areas (don't want them). I then decided to skip the "stock" outter shafts and decided to run the Dana 70 outters (Spicer Part # 382871) which are 35 spline and are a excellent "upgrade" for the Chevy/Dodge axles. The Ford Dana 60's need to do some "machine" work to make these 35 spline outters fit. To run the 35 spline outters you have to run "special" hubs currently only made by $ WARN $ so I got a set of them after doing some shopping around. I am now going to run the WARN 35 spline "slugs" that would replace the "Lock outs" because with the ARB in the axle I can "engage" it with a flip of the switch & with these in the front axle I won't have to mess with getting out to lock the hubs. I have a few friends who run different "Rock Crawling" events who use these with much success. Look at the pics below to see the new 1.71 axles.

<-Short side Spicer Part # 660182-1

 

Long Side Spicer Part # 660182-2 ->

 

Can we say bye bye to the old 30 spline stub shafts.......UPGRADE to these you will love it....ALL ABOUT BEEFY.....LOL

<-35 spline "outters" Part # 382871

 

 

35 spline "Lock Out" hubs Warn Part # 62672 for the 35 outters->
After I was able to locate a housing ( BOM # 610159 ) so I went ahead and ordered my "Kingpin Rebuid Kits" so I could go ahead and put all new bearings/seals before I put the knuckles on. You got to do some shopping around getting these because they can be pretty $ expensive $ in price. I made a few calls to get everything. I currently keep all the parts to rebuild your DANA 60 axle, e-mail me for details. I then decided to run the non-greasable u-joints (Spicer Part # SPL55-3x) because they have a forged cross. For those of you who want to run the greasable u-joints here is the (Spicer Part # SPL55-4x). Someday I will be running the famous "CTM" u-joints but at $300.00 each it won't happen anytime soon. I also plan on running Alloy front shafts but I figure these new shafts that I got should hold up fine but time will tell. I hate having to repair things in the woods but "S**T HAPPENS". Now I have all my axle shafts ready to put in the housing now it's time to get my $ ARB $ for the 60. I was able to find one for a good price so I ordered it I also got a master install kit also. When they come in the gears can be set up in the axle. Here are a few pics of the new parts that I got to rebuild both of the "top" & "bottom" King Pins. These are all Spicer Part #'s for those of you who need a certain part and for some of you who aren't to familiar with what they look like.

<-Spindle bearing kit Part # 700014

 

(TOP) King Pin knuckle bushing Part # 41886->

 

King Pin Part # 37302 ->

<-King Pin spring retainer Part # 620180

 

<-King Pin Spring Part # 37300

 

Dana 60 Spindle Part # 700013->

 

<-Inner Axle tube seals Part # 470682

 

(Bottom) King Pin bearing kit Part # 706395x->

 

<- (L) Inner Spindle Collar Part # 660568

<- (M) Outter Spindle Collar Part # 621027

<- (R) Spindle Nut Lock Washer Part # 621028

Ready to get put together.......
I hope these (Spicer) Part #'s help a few of you people who are ordering parts for their Dana 60. I even got the Part # for the front "locking collars" socket that I got from my local Advanced Auto...it's AMPRO PART # T 75868 at a surprising $18.00. Here is a exploded view of a Dana 60 front axle for you guys that need it to help you identify/install the parts. Keep reading below diagram for more of my build up.

<-Dana 60 Master install kit for the ARB

 

Dana 60 ARB new in box ready for install soon->
As you can see my ARB and Master install kit arrived already. For those of you who are looking to install a ARB in your Dana 60 front axle be aware of (2) different kinds depending on your gear ratio your running. The one kind takes the 4.10-3.73-ect. gear ratios and the other takes the 4.56-4.88-ect. gear ratios. I just purchased another Dana 60/14 Bolt axles with 4.56 gears in them and I think I will install this ARB in that 60 axle when I get it here and ready to start the ARB install. I am currently working on my Hi-Steer/Cross-Over arms for the 60 so they are ready to put on when the time comes. I will be also be installing a "Hydraulic Assist" ram on this axle to help steer it in "tight" trail conditions. Keep reading below...

<-35 spline Warn "Drive Flanges" that I'm gonna run in front instead of the Lock Outs pictured above

 

39.5x18x16.5 Boggers on Custom Hummer Rims will be running on the "Ultimate 60"->

Here we go....I FINALLY get everything cleared to install my ARB in the 60 on a Sunday. After doing everything like they tell you in the install booklet to get the diff. in carrier widths I press everything on the ARB and go to install the ARB in the housing-IT WON'T FIT! So after all of the shims are taken off the ARB and the bearing are pressed back onto it-IT STILL DOESN'T FIT!! I am beginning to RAGE here now. I measure the open carrier and then measure the ARB with everything together and the ARB is .322 wider than the housing!!! Of couse It's a Sunday and ARB "Tech" isn't open so I'm Boiling now. I waiting until Mon. after lunch to call the ARB "Tech" in WA. state and they tell me that there was supposed to be a "bearing" in the box with the locker (DUH). I ask him where does it go and he says on the D-side of the carrier where the "master shim" is located on so the bearing in "narrower" than the master install bearing that I been playing with all day Sunday! This is why it woudn't fit in the housing. So I get him to send me the "correct" bearing ( Timken Part # 387A & 382A ) to make this fit...a week later it shows up! While I'm waiting to get this **** bearing the SKY opens up with RAIN for a WEEK so long story short I ain't working in the rain. While the weather was bad I went ahead and painted my housing and outter knuckle componets after "prepping" them for the $$ POR15 $$ I was gonna put on everything. Doing all the prep work is a PITA but after everything is painted and dry it's well worth it. One things for sure WEAR GLOVES because that stuff DOES NOT COME OFF! After getting the new bearing to put on the ARB it fit like a glove ( HINT-notch bearing cap higher than in the pic because the diff. cover fill plug hits the copper line routed like the pic shows). Now that the ARB is in I can put the 60 outters together with new "Kingpin Rebuild kits". That stuff is pretty straight forward to put back together. I was able to sell my 44HD & the rear 14 Bolt. Here is a pic below of the ARB and the front gone. I am going to install F-250 shock towers on the front so I can run some Rancho 9000's and these will allow me more shock-wheel travel.

<-ARB is now sitting where it needs to be

 

FINALLY removed the 44 ready for the 60's new home :) ->

<-It might be hard to tell but it's now bolted in the front.

 

I have it sitting on stock tires while all the other "mods" are done.->
Well it has been about 2 years since completion of the front axle and I have changed a few things since the first buildup.  As soon as I got it on the road the "Drive flanges" that I put in the front had to be switched out for some 35 spline warn lockouts.  The flanges would make the front spin like it was locked in all the time causing my front driveshaft to "howl" at me going down the road.  After getting that fixed everything was fine for a long time until I wanted to put some Yukon 4140 Alloy shafts inner and outter which are way stronger than stock and also have a warranty on them.  I also started rolling on 35 Boggers at first and they lasted until they were just about slicks.  When it was time for the new tires I decided to run the new 38.5 x 15 x 15 Boggers on it and I fell in love with those tires Interco finally got a Bogger that rides great and is even "siped" on the lugs for better traction on the rocks and in wet street conditions.  I have ran all the other size boggers and 38.5 is where I am staying from now on and they balanced with very little weight on them.  They rode VERY smooth and no one believed me until the rode in it then they were amazed too.  I have a new set of 38's sitting in storage now and I am currently sitting on some 37 x 13.50 x 15 Baja Claw Radials which I got on a smoking deal from 4WP.  I wanted to get the 38's but at nearly $400.00 I didn't want them that bad and the 37's were only 200.00 each!  I hope to run these for a while and have the Boggers for the serious playing when needed.  I even finally built the front bumper the way I designed it in my head.  Here are a few pics of the front finished below....enjoy   

<-Front bumper all done

 

Front axle all done->