Lower kingpin problem

[87Mudder]

Alright....I needed to change the lower kingpin on the pass. side of my Dana 60. So I go to remove the 4 bolts holding the lower cap on the bottom of the steerin' knuckle and surprise, surprise...I shear the head off of bolt #1....and #2.....and #3....and #4! Why did I continue to break them off? Well, aside from the fact that I had been downing Budweiser all day prepping for the race here in Richmond, I had total disregard for basic mechanics and was turning the bolt to the right! What a genious I am.....Long story short, I need to know how to get these bolts outta' the lower plate and knuckle without destroying the inner threads in the knuckle. It'll be tough to drill 'em out as there is about 10 inches between the bottom of the knuckle and the ground. Thanks in advance and please feel free to make light of my drunken stupidity as well!!!!!!!!

 

[ryoken]

center punch, brand new quality drill bit, heat and an E-Z out...

 

[Mudstud]

Damn dude! First off, is there any stud sticking out that you could grind a thin slot into and try using a screwdriver to get them out? If you can get the knuckle off the truck and set it up on a drill press I think you'll have a decent chance of getting them all out. Drilling square is the trick and keep upping the size to get the largest hole in them. Then do the easy out.

 

[79k54life]

I've broke two on my dana 60 project. They were so bonded by rust that two broke. I tried an easy out with no luck. So about 8 hours later with alot of light and a small chisel, out they came. I would suggest a torch and a easy out first. I feel for you man, good luck.

79k54life

 

[87Mudder]

Damn dude! First off, is there any stud sticking out that you could grind a thin slot into and try using a screwdriver to get them out? If you can get the knuckle off the truck and set it up on a drill press I think you'll have a decent chance of getting them all out. Drilling square is the trick and keep upping the size to get the largest hole in them. Then do the easy out.

Correct me if I'm wrong, but in order to get the knuckle off don't you have to get the king pins out? I can't get the knuckle off right now because of the sheared cap bolts....Thanks!

 

[sweetk30]

finish poping the knuckle off and then plug weld some nuts to the broken bolts. let them cool. then heat the area around them and get it nice and hot. then try to remove one at a time. this might take 2-3 nuts each bolt. i do this all the time at work. its fast and basicly easy to do.

if not ebay has new n.o.s. mill knuckles for 60 or so on all the time. http://cgi.ebay.com/ebaymotors/NEW-GM-DANA-60-DRIVER-SIDE-KING-PIN-STEERING-KNUCKLE_W0QQitemZ190110742152QQihZ009QQcategoryZ33728QQssPageNameZWDVWQQrdZ1QQcmdZViewItem

http://cgi.ebay.com/ebaymotors/CUCV-R-H-Knuckle-for-Dana-60-frt-axle-Army-Military_W0QQitemZ290115397466QQihZ019QQcategoryZ33728QQrdZ1QQcmdZViewItem

 

[sandawgk5]

If all 4 of the bolts are twisted off at the head then the lower kingpin will come right off. It might require a prybar or something between the cap and knuckle but it will come off. Once it is off remove the knuckle as was said before and put it on a work bench.

Ira

 

[Mudstud]

Yes you do need the bottom cap off before you can swing the whole knuckle up and out. If you don't have any bolt heads holding the lower pin on (and it's not falling apart all ready) take a chisle and delicatety encourage the cap to come off. Work one side then the other. Once it's out the whole knuckle will come off. Then you will likely have enough material to thread on a nut and do the plug weld. I forgot about that way of extraction though I have had good success with that method.

 

[sandawgk5]

Another thing to do is to remove the upper kingpin cap to remove the preload on the knuckle that should help get the lower pin out with minimal effort. The upper has to be removed to get the knuckle off anyhow.

Ira

 

[Rob 85K5]

The upper has to be removed to get the knuckle off anyhow.

Ira

Not necesarily, I have 2 stuck studs and nuts on the top arm that are now rouded out. If you beat the lower hard enough it will swing out so you can lift the knuckle up off the upper kingpin.

 

[sandawgk5]

Not necesarily, I have 2 stuck studs and nuts on the top arm that are now rouded out. If you beat the lower hard enough it will swing out so you can lift the knuckle up off the upper kingpin.

OK so it is not mandatory but it makes it easier

Ira