I finally got the front end back together with the new 5.13's and reinstalled in the truck, 1" farther forward courtesy of the ORD axle spacer plates.
It was in desperate need of attention, I ended up having to replace almost everything. I was able to reuse the drivers side wheel bearings and the spindle bearings. All the other bearings/seals were toast. I found a used good condition stub shaft on Pirate to replace the one that had a twisted spline and swapped it in.
I used two floor jacks to scoot that heavy beotch around from the garage and into position under the truck. That worked surprisingly well.
Yes my cracked and broken grill is being held in place partially with a piece of old baling twine, bottom center.
Brand new front shaft I had built last year and had never installed.
New stance with axle pushed forward 1"
Filled the Dana 60 up with gear oil and went for a nice little 20 mile break-in drive with the hubs locked in and in 4-hi on a dirt track through the local mountains. Everything seemed to be working good. Feels good to have a fully functional 4x4 again.
I have about 200 miles on the new rear 5.13 gears now, so a ways to go with the break in miles.
Lots more to do on the truck,
@blazinzuk (Big Thank You, Eric) is hauling a NV4500 home for me from his big adventure this weekend so I will be working on that swap soon. I have a front bumper build/winch install in the works too.
Next up is getting the rear driveline angles set to a happier place.
Looking for ideas for a softer flexier rear suspension but still being able to use it as a hard working truck... maybe air bags? Links are not on the agenda.