Full Dana 60 Rebuild DIY

Introduction

This tutorial provides a comprehensive guide to rebuilding a Dana 60 axle, based on the detailed DIY video from Offroadfarm. Whether you're a seasoned mechanic or a DIY enthusiast, this step-by-step guide will help you understand the process and ensure you have the right parts and tools for a successful rebuild.

Step 1: Gather Necessary Tools and Parts

Before starting the rebuild, make sure you have all the required tools and parts. Here’s a checklist:

• Tools Needed:

  • Torque wrench (½ inch and in/lb)
  • Bearing puller
  • Bearing packer
  • Seal driver kit
  • Impact wrench (½ inch and 3/8 inch)

• Parts Needed:

  • Bearings (carrier and pinion)
  • Seals (inner and outer axle seals)
  • Locker (if applicable)
  • Spindle, wheel bearings, and kingpin parts

• Recommended Suppliers:

  • Offroad Design for parts and kits
  • Additional tools can be found on Amazon or local auto parts stores

Step 2: Disassemble the Old Axle

Begin by carefully disassembling the old Dana 60 axle. Follow these steps:

1. Remove the Wheel:

   • Jack up the vehicle and secure it with jack stands.
   • Remove the lug nuts and take off the wheel.

2. Take Out the Brake Assembly:

   • Unbolt the brake caliper and rotor.
   • Set them aside safely.

3. Remove the Spindle:

   • Unbolt the spindle from the axle housing.
   • Take care not to damage any surrounding components.

4. Extract the Axle Shafts:

   • Pull out the axle shafts from the differential housing.
   • Be cautious of any fluid leaks.

5. Disassemble the Differential:

   • Remove the cover and drain the gear oil.
   • Carefully take out the ring gear and differential assembly.

Step 3: Clean and Inspect Components

After disassembly, clean all parts thoroughly and inspect them for wear or damage.

• Use a solvent or parts cleaner to remove grease and dirt.
• Check bearings, seals, and gears for signs of wear.
• Replace any damaged components with new parts from your gathered list.

Step 4: Rebuild the Differential

Now it's time to rebuild the differential.

1. Install New Bearings:

   • Press in new bearings onto the differential and pinion.
   • Use the bearing driver kit for proper installation.

2. Set Pinion Depth and Preload:

   • Adjust the pinion depth according to factory specs.
   • Use an in/lb torque wrench to set the pinion bearing preload.

3. Install the Ring Gear:

   • Attach the ring gear to the differential.
   • Use the specified torque values for all bolts.

Step 5: Reassemble the Entire Axle

With the differential rebuilt, reassemble the axle.

1. Reinstall the Differential:

   • Place the differential assembly back into the housing.
   • Secure it with the cover and ensure it's properly sealed.

2. Install Axle Shafts:

   • Slide the axle shafts back into place.
   • Make sure they seat correctly and secure them with the appropriate nuts.

3. Reattach the Spindle and Brake Assembly:

   • Bolt the spindle back onto the axle housing.
   • Reinstall the brake rotor and caliper.

4. Final Checks:

   • Ensure all bolts are tightened to the correct torque specifications.
   • Double-check the fluid levels in the axle housing.

Conclusion

Rebuilding a Dana 60 axle can be a rewarding and educational DIY project. By following these steps and using the right tools and parts, you can successfully reassemble your axle for improved performance. Always refer to the Dana 60 bible and consult with parts suppliers if you have questions. Happy rebuilding!