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Old 03-12-2015, 06:04 PM   #6
1project2many
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Join Date: Mar 2012
Location: Lakes Region NH
Posts: 3,158
Re: Dana 60 gear swap

Ring & pinion is expensive. Labor to properly disassemble, clean, and set up can be 4 hrs to 8 hrs with clean, running axle on the low end. Make a mistake and chew up parts and repair cost is usually more than cost of pro install.

You'll need the gears and a shim set at a minimum, with complete install kit being preferred. Spare bearings can help because, as mentioned above, you need to use trial and error method to determine which shims are appropriate. Make sure to clean, clean, clean the housing. Then clean it again. Nothing will ruin an install faster than leaving metal in the axle housing. Dial indicator is a must. Calipers or micrometer is nearly impossible to do without. Checking pinion preload requires special tools or someone who already has a feel for it. Lotsa pictures of gear patterns will help when setting up gears. Check pattern first, take pictures, and measure clearances. This can help you decide what's OK if new parts aren't quite up to specs (it happens!). Carefully not positioning and placement of parts, order of parts, etc. Take notes. Be sure to measure all shims that are removed in order to get correct starting point. Note that pinion depth shim under bearing cone can be replaced with pinion depth shims under cup. Ultimately the job can be done at home but really best to find someone with experience to help and check work. Post updates if you do it here and don't be afraid to ask more questions.

Dana 70 is close to 60.
http://www.billavista.com/tech/pdf_i...Model%2070.pdf

Note about using cup or cone pinion shims
http://www.billavista.com/tech/pdf_i...xl-Tec-12).pdf

Military manual, shows Dana repairs of 60/70. Use sections for M1028A2.
http://www.billavista.com/tech/pdf_i...on%20Axles.pdf

And the awesome reference page these can all be found at:
http://www.billavista.com/tech/pdf_i...ars/index.html

Last edited by 1project2many; 03-12-2015 at 06:09 PM.
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