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Dana 60 build

53chevy

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Starting to tear down my dana 60 front axle to give it some love. Any suggestions on parts?
I have
Yukon 4340 35 stub / inner shafts
Yukon lock out hubs
Reid racing knuckles
Ried racing bronze bushings
Ctm u joints
Arb locker
Ord dana 60 seals
Full timkin rebuild kit
Im reusing my 5.13 gears that are still in good shape.
Thanks
 
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You're running 4340 stubs and ctms. Why ruin a set of stock inners when they break? Lose the expensive knuckles and put 4340 inners in it.
 
The tube end seal is super nice. Forgot where I seen them but am planning on getting them on my 60. And I second the knuckle vs shaft trade-off. Gusset your factory knuckle and that's plenty strong unless your balls to the walls all day.
 
You're running 4340 stubs and ctms. Why ruin a set of stock inners when they break? Lose the expensive knuckles and put 4340 inners in it.

Agreed. I doubt they'd warranty the joint if it's damaged by a stock inner during a failure.
 
What point in the driveline do you guys think would be the "best" weak point to make , something is going to give eventually in the system.
 
I have 1350 driveshaft joints and still broke a chromo short side. Not sure a weak link worked. What's gonna give is your right foot. Don't use so much.
 
Personally, I don't like intentional weak links. I prefer to not break if I can.

But, living in the real world, it still happens sometimes. Your build list is really solid, that makes for a really strong front D60.

Mine is similar, GM D60 (low pinion), Reid knuckles, Superior 35 spline inner/outer 4340 shafts, Yukon super joints, drive flanges (I've never seen a broken set of Yukon hubs so I wouldn't sweat that), etc. From your build list, I'd bet you'll find the ring and pinion is the next weak link like I did late last year:



I ended up replacing it with the Jana 76 stuff (i.e. D70 ring and pinion in the D60 housing) plus a load bolt on the back side (also from Jantz, I think this does even more than the bigger ring gear). Honestly, the ring/pinion I broke was OE from the late 70's and I've been wheeling on it for ~10 years with 42's, so I don't think it owed me much. I decided it was worth the insurance, I wheel my Blazer harder than ever now and with sticky 42's and 600+ hp, aside from running laps on the hardest trails out here, I don't anticipate being easier on parts anytime soon.

If you're not as hard on your stuff as I am, you'll probably be fine with your list as-is.

The rest of my front D60 has been rock solid, I haven't broken a shaft/knuckle/whatever since its had good aftermarket stuff.
 
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Ive looked at the jana 76 before but im going to hold off on that venture. Thanks for all the input
 
K3500 4 door long bed, most likely 44" boggers with a 632ci bbc under the hood
 
Watch out for the ring and pinion, that will be your weak link. Front diffs with a low pinion shouldn't have ever been built.
 
This brings me to the question of when does the HP60 fail vs the LP60 as far as ring and pinion go
 
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