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Shakerbuilt Projects
"Bulletproof"  PART 3 (continued)

Dana 60 Build Up

By: Tim Fryer "Shaker"
Built by Gibsonwebsolutions.com © 2009-2010
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.
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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.
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.
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