I finished installing the D60 today. Here is an explanation of the swap:
I started with an unlocked stock D60 with 4.10's. I stripped it down (not including the gears) and replaced the wheel bearings and seals, turned the rotors, installed rebuilt calipers with new pads, rebuilt the king pins, replaced the right tie rod end, and installed the steering arm on the right side for the crossover. I did all this in the comfort of my garage:grin3: . All parts which were retained were sent to my son's shop and cleaned in one of those fancy dishwasher-style parts washers. Boy did the hubs need that! New o-rings were installed on the manual hubs. Oh yah, I replaced the axle u-joints with Spicer non-greaseable joints.
Meanwhile, I purchased a 2wd gearbox. In the driveway, I removed the corp. 10 bolt, steering gear, and front spring shackles and bushngs (the ones in the frame). When attempting to install the new steering gear, I screwed up some of the threads and had to go buy a tap. After cleaning up the threads, I installed the new box along with a steering box brace from Offroad Design. I installed greasable spring bushings, also from ORD. During this process, I checked the other spring bolts and found one finger tight. I removed the bolt and inspected it, finding it to be fine. It was re-installed using Locktite Red.
Time to slide the D60 in there:drool: . Using two jacks, I positioned it under the springs and bolted them in. It sounds easier then it was. Good thing I'm in good shape and can bench press an elephant
.
When I got ready to bolt up the right side, I discovered that the studs that came in the u-bolt kit were too long :wall: . Back to Fasteners for shorter studs. After that, it bolted right up.
The next problem was discovered when bolting up the front u-joint. It seems that someone had replaced the pinion yoke with one for a larger u-joint. Normally this is a good thing. However, I don't have a driveshaft with the larger u-joint. So, I picked up a new yoke only to find out that I don't have a socket to fit the nut:wall: . I found a 1 5/16 socket at Pricebusters. And it had already been clearanced to fit (10 bucks)
. I changed the yoke and bolted up the d-shaft.
Greased everything and bled the brakes. I filled the p/s pump with fluid and stared the engine. The pump aerated the fluid and made a big mess. It took a while, but the pump quieted down and the steering turns smooth.
I double checked all the bolts and nuts and mounted the tires. Took it off the jack stands and took it for a drive. The steering feels VERY nice! It is nice and tight and has no pump steer (duh). Tested out the 4wd - it sounds good. I flexed it on a snow bank and what do you know, the steering wheel did not turn as the suspension flexed . Now I have to clean up the driveway and garage floor:i2:
I have only three concerns and/or questions: 1) since the brake lines bolt to the top of the D60 calipers instead of the side like on the 10 bolt, the rubber is a little to short. I will have to have new extended lines built, but for now I will take the clip off at the frame so there is some slack. 2) the brake pedal is a little soft. I am going to have the brakes power-bled and go from there (the M/C is only three months old). Will I need a one-ton M/C? 3) when bolting the shocks to the axle, the mounts were wider than the 10 bolt. Is there a spacer that is normally on a D60 that I need to find and buy?
Thank you to everyone here who answered my questions along the way!
And thanks for indulging me on this long read. I can't wait to get out and wheel!
I started with an unlocked stock D60 with 4.10's. I stripped it down (not including the gears) and replaced the wheel bearings and seals, turned the rotors, installed rebuilt calipers with new pads, rebuilt the king pins, replaced the right tie rod end, and installed the steering arm on the right side for the crossover. I did all this in the comfort of my garage:grin3: . All parts which were retained were sent to my son's shop and cleaned in one of those fancy dishwasher-style parts washers. Boy did the hubs need that! New o-rings were installed on the manual hubs. Oh yah, I replaced the axle u-joints with Spicer non-greaseable joints.
Meanwhile, I purchased a 2wd gearbox. In the driveway, I removed the corp. 10 bolt, steering gear, and front spring shackles and bushngs (the ones in the frame). When attempting to install the new steering gear, I screwed up some of the threads and had to go buy a tap. After cleaning up the threads, I installed the new box along with a steering box brace from Offroad Design. I installed greasable spring bushings, also from ORD. During this process, I checked the other spring bolts and found one finger tight. I removed the bolt and inspected it, finding it to be fine. It was re-installed using Locktite Red.
Time to slide the D60 in there:drool: . Using two jacks, I positioned it under the springs and bolted them in. It sounds easier then it was. Good thing I'm in good shape and can bench press an elephant
. When I got ready to bolt up the right side, I discovered that the studs that came in the u-bolt kit were too long :wall: . Back to Fasteners for shorter studs. After that, it bolted right up.
The next problem was discovered when bolting up the front u-joint. It seems that someone had replaced the pinion yoke with one for a larger u-joint. Normally this is a good thing. However, I don't have a driveshaft with the larger u-joint. So, I picked up a new yoke only to find out that I don't have a socket to fit the nut:wall: . I found a 1 5/16 socket at Pricebusters. And it had already been clearanced to fit (10 bucks)
. I changed the yoke and bolted up the d-shaft. Greased everything and bled the brakes. I filled the p/s pump with fluid and stared the engine. The pump aerated the fluid and made a big mess. It took a while, but the pump quieted down and the steering turns smooth.
I double checked all the bolts and nuts and mounted the tires. Took it off the jack stands and took it for a drive. The steering feels VERY nice! It is nice and tight and has no pump steer (duh). Tested out the 4wd - it sounds good. I flexed it on a snow bank and what do you know, the steering wheel did not turn as the suspension flexed
. Now I have to clean up the driveway and garage floor:i2: I have only three concerns and/or questions: 1) since the brake lines bolt to the top of the D60 calipers instead of the side like on the 10 bolt, the rubber is a little to short. I will have to have new extended lines built, but for now I will take the clip off at the frame so there is some slack. 2) the brake pedal is a little soft. I am going to have the brakes power-bled and go from there (the M/C is only three months old). Will I need a one-ton M/C? 3) when bolting the shocks to the axle, the mounts were wider than the 10 bolt. Is there a spacer that is normally on a D60 that I need to find and buy?
Thank you to everyone here who answered my questions along the way!
And thanks for indulging me on this long read. I can't wait to get out and wheel!
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