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1990 K5 Blazer Project "Side-Chick"

Aptly named because this project is taking all the time and money that should be spent with my family, LOL! The plan for this truck is going to be an adequate trail rig thats still nice enough, and comfortable enough for my family to enjoy with me.
Overview Gallery Discussion
OK, so I saw a pic of your 14 bolt on page 1 with the perches not on, so yeah just install your SYE and CV shaft and set the truck down on its weight and measure/adjust the pinion slightly (1-2 degrees) below the drop of the driveshaft tube. And burn the perches on. Use your angle finder on the flat of the diff yoke when it is the position its sitting how it is in those last few pics you posted.
 
I am running a 1410 double cardan and a SYE, the rear pads are in the stock location. Runs smooth at 80mph.
 
I have looked, and haven't found a distributor for them. If you find a vendor, let me know.

I found them on craigslist.
 
Alright, sounds like I need to wait until I have driveshafts made to weld in the perches and finalize the rear shocks.

So I finally got the gumption to rip out the D60 and get it rebuilt. It's all blasted apart and got the housing painted. Tomorrow I'm going to start final assembly.

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How clean do these bearing journals need to be? I have all the built up corrosion buffed off. But not sure if I need to buff it all out?

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I would run those as is pictured. I would not sand or buff on them too much. My opinion would be if they are clean and wire wheeled, build away. That is me and how I would run it.

Oh, and I couldn't find a lead on those tires. Seems like they were around in the US a few years ago and now gone in that size.

How did the carrier come out for you? Was it pretty tight? Most the Dana 60's I've worked on were in there pretty good.
 
I sincerely think that "bubba" put this axle together. Home made shims, no crush sleeve, backlash was WAAAY over tolerance.

So, the carrier came out pretty easy. A little jerk with a prybar, and out she came.

I've been loading up on videos to prep for this rebuild, so I was expecting a battle.
 
Yeah, I bought a case spreader just for my Dana 60 Front after the last few I did without one. Even with spreading the case about .007" the carrier needed a good pry on mine.
 
Need some help from the members. My internet searching is just leaving me confused and frustrated.

Critical info:
Dodge kingpin low pinion dana 60 (pre-1993)
Yukon gear install kit
USA gear R&P (5.38 if that matters)

I'm trying to find an average ballpark to begin setting my pinion preload.

Previous owner did not install a crush sleeve or a shim kit. So I don't have a "baseline" to do the first trial. How should I begin this?

Also, it doesn't look like there is room for the crush sleeve and the bearing?

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I think the bearing pre load on the older dodge dana 60s is set with shims.
 
20210224_161429.jpg 20210224_161421.jpg Alright gearheads: second opinion? I'm hoping this is good, because I've been fighting it for 2 days. This is the best pattern I've got so far.
 
I feel like the pattern is good toe-heel, but I'm still getting a sharp line at the root. Didn't seem to change as I adjusted pinion depth.
 
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