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Understanding axle gear magic/vodoo

Rugby_7

Rugby_7

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I'm getting ready to go through the dana 60 I picked up. Inside the housing was some rust and crud so I want to remove the carrier to check things out. I am wondering to what point of replacing stuff do I need to reset backlash and do gear pattern stuff? I would be replacing the caps in the exact same spot as removed with proper torque.
1. If I pull the carrier and everything looks good can I re install carrier with caps in exact same spots, re torque to spec, and be good to go? I would replace oil seals same time.
2. If the carrier bearings need replacement can I switch them out for new ones and re install and be good to go?
3. If the inner pinion bearing needs to be replaced can I re install and be good to go?

I've been going through the gear setup bible. This is something I have never done before but would like to learn how to do. So what better way to lean than to do it.
 
If you don't replace bearings, you're definitely ok to just reinstall everything.

If you do replace bearings, it would be smart to re-check all the specs but they should all stay the same (bearing tolerances are usually really good, so changing bearings rarely means re-shimming anything).

If you were changing the gear ratio, you'd almost certainly be in for changing shims but if you're just R&R parts, you should be fine.
 
1977k5 said:
If you don't replace bearings, you're definitely ok to just reinstall everything.

If you do replace bearings, it would be smart to re-check all the specs but they should all stay the same (bearing tolerances are usually really good, so changing bearings rarely means re-shimming anything).

If you were changing the gear ratio, you'd almost certainly be in for changing shims but if you're just R&R parts, you should be fine.
Click to expand...

^ This
 
Does this still apply if you use the same gears but install a new carrier??
 
1977k5 said:
If you don't replace bearings, you're definitely ok to just reinstall everything.

If you do replace bearings, it would be smart to re-check all the specs but they should all stay the same (bearing tolerances are usually really good, so changing bearings rarely means re-shimming anything).

If you were changing the gear ratio, you'd almost certainly be in for changing shims but if you're just R&R parts, you should be fine.
Click to expand...

Thanks Chris! Exactly what I needed to know!
 
If you replace carrier you should recheck gear pattern and backlash and go from there
 
also if the carrier is out time for NEW AXLE TUBE SEALS .

if you don't and get it all back together then 1 week later find a tube has gear oil coming from it you will kick your self in the butt.

and dana 60 use the newer ford seal . little harder to install but a lot better design .
 
sweetk30 said:
also if the carrier is out time for NEW AXLE TUBE SEALS .

if you don't and get it all back together then 1 week later find a tube has gear oil coming from it you will kick your self in the butt.

and dana 60 use the newer ford seal . little harder to install but a lot better design .
Click to expand...

Would that seal be from the late 80s early 90s ford Dana 60s or newer than that?
 
Super duty era I believe.


FYI. Ive done the locker/carrier change. With a different carrier or locker you will only need to check backlash. It doesnt affect pinion depth/pattern at all in that aspect. If you're carrier isnt running true you've got way bigger problems than your pattern lol.
 
they are tricky to push in place . make sure to do the best by pushing in on the outer lip / body of the seal . .
 
The biggest variable in the whole setup is the axle housing. The gears are machined to very good tolerances and the carriers are pretty good. So most of what the factory shim packs are doing is accounting for the axle housing. This is why when you swap gears the old shim set is usually pretty close to your final configuration. Swapping carriers is similar, but you may adjust a little further from there. This is why you usually start by reusing the old shims and then adjust from there.
 
Blue85 said:
The biggest variable in the whole setup is the axle housing. The gears are machined to very good tolerances and the carriers are pretty good. So most of what the factory shim packs are doing is accounting for the axle housing. This is why when you swap gears the old shim set is usually pretty close to your final configuration. Swapping carriers is similar, but you may adjust a little further from there. This is why you usually start by reusing the old shims and then adjust from there.
Click to expand...

Exactly. Thats why when you try to setup gears by doing checking height math its so much easier with marked gears.
 
Rugby_7 said:
I'm getting ready to go through the dana 60 I picked up. Inside the housing was some rust and crud so I want to remove the carrier to check things out. I am wondering to what point of replacing stuff do I need to reset backlash and do gear pattern stuff? I would be replacing the caps in the exact same spot as removed with proper torque.
1. If I pull the carrier and everything looks good can I re install carrier with caps in exact same spots, re torque to spec, and be good to go? I would replace oil seals same time.
2. If the carrier bearings need replacement can I switch them out for new ones and re install and be good to go?
3. If the inner pinion bearing needs to be replaced can I re install and be good to go?

I've been going through the gear setup bible. This is something I have never done before but would like to learn how to do. So what better way to lean than to do it.
Click to expand...

NEVER assume it will be good, ALWAYS recheck all clearances. Changing ANY piece or disassembly of anything could mean re-setting clearances.
 
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