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Dana 60 metal grinding.

ZombieK5

ZombieK5

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Put Spindles on the Dana 60 today. No issues but the driver side now has a metal on metal grinding when I turn pinion with my hand. The axle splines stick out 1 5/8" while the pass side is 1 1/2"

Shaft won't go in any further. Not sure where is grinding. Really don't want to take Spindle off again.

Spindle bearings are new. Here are photos. I am using the ORD "Improved" Spindle Seal. Everything is lubed. I'm at a loss for what's grinding

20230604_110047.jpg

20230604_110051.jpg

20230604_110956.jpg

20230604_161749.jpg
 
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Could the knuckle studs be touching the hub or something? There looks to be a ton of thread outboard of the spindle nuts.

“Rear” D60? What are you building?
 
So you’re getting a metal scrubbing as pictured? Are the axles touching the inside of the knuckle?
 
nvrenuf said:
So you’re getting a metal scrubbing as pictured? Are the axles touching the inside of the knuckle?
Click to expand...
They dont seem to touch. They spin fine, no resistance other than preload. I am absolutely mystified. im gonna take spindle off tomorrow or Tues.

Anyone else have any ideas before I take it all apart again?
 
Yoke on the housing?
Ring gear on an aftermarket cover?
 
1 side or both?

Could the new style spindle seal push the axle against the end of the tube?
 
nvrenuf said:
1 side or both?

Could the new style spindle seal push the axle against the end of the tube?
Click to expand...
Took off the spindle and turned the shaft....NO GRINDING.

It almost seems like the splines are grinding against the bore of the spindle. There are circular scratches (for lack of a better word) inside the bore. The front axle was working fine when when it was tore down.....WTF?
 
frankin5 said:
Have you tried centering the spindled shaft and rotating it? The locking hubs do that when they are installed.
Click to expand...
No, not yet. However, the internal Spindle bearing should also center the stub shaft. The passenger side is silent...just a little confused. Really don't want to get it put totally together IF there is an issue. After work I'm gonna get my digital caliper out and measure the bore diameter and shaft diameter.
 
ZombieK5 said:
No, not yet. However, the internal Spindle bearing should also center the stub shaft. The passenger side is silent...just a little confused. Really don't want to get it put totally together IF there is an issue. After work I'm gonna get my digital caliper out and measure the bore diameter and shaft diameter.
Click to expand...
Just a thought - you mentioned that you had differences in the stub shaft splines sticking out of the end of each spindle.
Although the ISB does a decent job of keeping the shaft centered there is a need for the end of the shaft to be supported - perhaps the stub shaft that is grinding is the one with the lesser amount of shaft sticking out and therefore not as well supported by the ISB and causing the scrubbing on the inside of the outer portion of that spindle like was mentioned earlier.
Just something to consider…
 
tarussell said:
Just a thought - you mentioned that you had differences in the stub shaft splines sticking out of the end of each spindle.
Although the ISB does a decent job of keeping the shaft centered there is a need for the end of the shaft to be supported - perhaps the stub shaft that is grinding is the one with the lesser amount of shaft sticking out and therefore not as well supported by the ISB and causing the scrubbing on the inside of the outer portion of that spindle like was mentioned earlier.
Just something to consider…
Click to expand...

I am going to remove the other spindle and recheck everything. I am reluctant to take the shafts out again...really don't want to damage the new internal seals. I will take measurements after the shafts are removed...I'll see if I can push one or both shafts in further and see where that gets me.
 
ZombieK5 said:
I am going to remove the other spindle and recheck everything. I am reluctant to take the shafts out again...really don't want to damage the new internal seals. I will take measurements after the shafts are removed...I'll see if I can push one or both shafts in further and see where that gets me.
Click to expand...
Before ya’ take the spindles off try and ( on the side making noise ) push the axle out as much as possible either by hand or pry bar at the axle joint with the knuckle perfectly straight and wrap a shop towel around the stub axle at the splines inside the outer portion of the spindle - and then rotate the shaft. If there is no scrubbing noise then you know it was the stub shaft on the spindle wobbling around.
It’s worth a try.
 
tarussell said:
Before ya’ take the spindles off try and ( on the side making noise ) push the axle out as much as possible either by hand or pry bar at the axle joint with the knuckle perfectly straight and wrap a shop towel around the stub axle at the splines inside the outer portion of the spindle - and then rotate the shaft. If there is no scrubbing noise then you know it was the stub shaft on the spindle wobbling around.
It’s worth a try.
Click to expand...
Thanks.

I'll give that a shot this weekend. IF that doesn't work, I'll leave everything the way it is and install the hubs and The Hub locks and see what happens. Worst case scenario it will give me practice installing everything, removing everything and installing it again.
 
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