Got my butt kicked by the dana 60...

[elks]

So I eventually won the contest but not after I few choice words (said under my breath so students could not hear). We are currently taking down our dana 60. today we were on the last steps of pulling the knuckles off etc. the tops were a piece of cake... But the bottom was a different story all together.

the lower cap was stuck on. the build thread we were using as a guide said just take a screw driver and hammer tap it in and wedge it off. Well The first one came off after 40+ minutes of whacking. It took chisels, 3 screw drivers, a 4 pound sledge.... It also meant beating my finger a few times (insert the choice words under my breath here). I then went on to the next side... My for arm was burning/elbow hurting (baseball just started up and I am a coach)...

I had sweat dripping and began the next side. Same issues. After about 30 minutes I gave up for a bit... the kids all gave me crap, so I drank a mountain dew for that popeye effect. And in 20 minutes had the second off. So then I once again made my students to me...

In the process I chewed up the edges a bit. If I just touch em up with a grinder will they be OK to reuse?

Also how can you tell if you need to replace the actual metal king pin tapped top with the big allen? My plastic bushing is messed up on both sides so they need replaced.

 

[imiceman44]

So I eventually won the contest but not after I few choice words (said under my breath so students could not hear). We are currently taking down our dana 60. today we were on the last steps of pulling the knuckles off etc. the tops were a piece of cake... But the bottom was a different story all together.

the lower cap was stuck on. the build thread we were using as a guide said just take a screw driver and hammer tap it in and wedge it off. Well The first one came off after 40+ minutes of whacking. It took chisels, 3 screw drivers, a 4 pound sledge.... It also meant beating my finger a few times (insert the choice words under my breath here). I then went on to the next side... My for arm was burning/elbow hurting (baseball just started up and I am a coach)...

I had sweat dripping and began the next side. Same issues. After about 30 minutes I gave up for a bit... the kids all gave me crap, so I drank a mountain dew for that popeye effect. And in 20 minutes had the second off. So then I once again made my students to me...

In the process I chewed up the edges a bit. If I just touch em up with a grinder will they be OK to reuse?

Also how can you tell if you need to replace the actual metal king pin tapped top with the big allen? My plastic bushing is messed up on both sides so they need replaced.

First the King pin itself should be fine if it's still the right size, not worn down a lot and has no scars or groves.
As for anything external, I would grind smooth so that you don't have any place for stress cracks to form, and run it, worst case later if there is something wrong you can change it, but should be good most likely.
Of course a pic would help us more give you the right advise.

 

[Z71paramedic]

I had the same symptoms with my lower caps but I gave up on it. I didn't feel like breaking anything and my axle only had 11k miles on it, so I replace the upper springs/bushins and threw it back together. I'll redo them in a while when I clean it up and paint it, but I just didn't feel like messing with it at the time

 

[elks]

First the King pin itself should be fine if it's still the right size, not worn down a lot and has no scars or groves.
As for anything external, I would grind smooth so that you don't have any place for stress cracks to form, and run it, worst case later if there is something wrong you can change it, but should be good most likely.
Of course a pic would help us more give you the right advise.

Awesome... We will be in the shop later tonight and working so I will take pics and post em then... I will look it all over. Also is it possible to just buy/get plastic cover? Will I need springs and all?

 

[imiceman44]

Awesome... We will be in the shop later tonight and working so I will take pics and post em then... I will look it all over. Also is it possible to just buy/get plastic cover? Will I need springs and all?

The plastic bushing is usually sold with new springs and it's not that expensive, I think it was $40.

 

[Hogback Fabrication]

The spring is typically the part that is bad even though they rarely break, they fatigue over time and don't put as much pressure on the bushing.

We have a spring and bushing kit that's $28 and covers both sides.