So a lot has happened over the last week, some decisions had to be made, but a lot was accomplished ...
We hauled all the parts to my friend's shop and began work on setting up the gears and locker for the Dana 60. The tooth pattern seemed alright by the end of the night, but the pinion preload felt too tight. We called it a night and got back to it the next morning. Put a deflection beam torque wrench on the pinion nut, and sure enough, we came out at 100-inch pounds, which was way to tight. Our hope was to be able to end the night before with the differential done and be able to end the day with the axle done, but with the pinion preload too tight and a work meeting interrupting our afternoon, we knew we weren't going to have the time we need. And I knew that I was going to have very limited time over the next month. So it was decision time. How much value is there in knowing how to set up my own gears and build my own axle? A lot. But how much more value is there in knowing it was done right by someone who knows what they are doing (which wasn't me) and done in a reasonable amount of time? Even more. So we loaded everything up and hauled it all to Drive Line Service of Jacksonville. Then I decided I would also let them do my 14 bolt. So that afternoon I yanked the rear axle out and hauled it over to them the next morning. They got the 14 bolt done in a day's time and the Dana 60 was done a week later.
Then I learned some things. Things that proved the urgency of going ahead and getting all this done now, rather than putting it off.
When I went to pick up the 14 bolt, which is a 47 year old axle, the guys told me it was ready to grenade at any moment. At least one of the pins in the spider gears (I may explaining this wrong) had broken in half, along with a washer or two, and it was by the grace of God that it was all still holding together. But it's practically a brand new axle now, with 4.88 gears from Yukon, a Detroit Locker, a crush sleeve eliminator, new 1350 pinion yoke, Lube Locker gasket, and new diff cover and pinion guard from RuffStuff. I picked it up, brought it home, and slung it back under the truck so I could move the truck around. I went ahead and threw the 37s on the truck so that if I had to drive it anywhere I wouldn't be screaming down the road with 4.88s and 33s.
That's when I discovered the urgency of getting the Dana 60 done. I had already decided to get it done anyways, because for a while I was pretty certain I could hear grinding noises coming from the front end as I drove, but my suspicions were confirmed when I pulled the 33s off the front axle. The passenger side spindle and bearings are shot, as evidenced by significant play in the hub/wheel when not under load. So the decision was made then that the truck would not be driven until the 10 bolt was gone and the 60 was in. About a week later, the 60 was ready to be picked up.
A whole lot went into this axle. Except for the 1992 housing, everything is brand new: Ox Locker, 4.88 Yukon gears, 4340 Yukon shafts, 4340 35 spline Yukon stub shafts, all new kingpins, new outer knuckles, new spindles, ORD crossover steering, ORD HD tie rod and tie rod ends, new hubs, Yukon's heavy duty 35 spline locking hubs (not yet installed), new caliper brackets from RuffStuff, and new rotors ...
But wait, where are the rotors? And why are the caliper brackets on backwards??
I think the guys at the shop thought they were working on a DRW 60, not a SRW. No big deal. They got the important stuff right and I had the hubs off, caliper brackets swapped side to side, wheel studs out (borrowed a press from a friend) rotors added and had everything back together with wheel bearing preload set by midnight last night. And it was a good learning experience.
And that's where she sits now. Still need to get the Yukon locking hubs installed, and Ox is shipping me a modified shifting fork that can clear the internal bracing of the vent hole. Other than that, the Dana 60 is done. The truck is positioned and ready for front-end tear down, which will begin this weekend. I have a PSC ported steering box ready (in case I add hydro-assist later), as well as Bilstein 5125 long travel shocks, Ford towers, and DIY4x shock tabs. Just waiting for one more shipment from ORD and the front and rear springs can be yanked and all of this can start coming together.
Looking forward to getting it done.
Andy
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