Dana 60 Teardown - step by step - Toyota FJ Cruiser Forum
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post #1 of 23 (permalink) Old 01-20-2013, 08:47 PM Thread Starter
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Dana 60 Teardown - step by step

So, This probably isn't very applicable here but since I went through the effort to make it I thought I'd share for those interested, I'll show you how to breakdown a Chevrolet Dana 60 (or 1ton) front axle. Let the fun begin.

First step is getting your vehicle on a level surface, placing the axle on jack stands, and removing the tires.





Now that your tires are pulled you'll move to the break calipers. The nut that holds the caliper together will be removed with a 1/4" allen wrench. Once it's free use a bungee to hang it out of the way with out over extending the brake lines.





The drive cap will be removed with the same 1/4" allen wrench.



With the cap off just keep pulling the drive flange parts. Once the snap ring is off, you'll use the screws from the caps to pull the flanges.







With the flanges out of the way, the next step is removing the hub. You'll need a 6pin 2.6" socket to pull the spindle nuts.






Now that the hub is off, you'll use a 3/4" socket to free the spindle.




Now the spindle and seals will pull off.

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post #2 of 23 (permalink) Old 01-20-2013, 08:48 PM Thread Starter
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Re: Dana 60 Teardown - step by step

Now the axles will slide right out.



Pieces, and empty.




The other side will come apart exactly the same. Except you'll likely be doing this to remove or change a broken axle. In this case it tis the passenger inner axle that is broken. We will resume at that step from above.

Using a drop light you'll see your broken axle shaft. Clean debris.




Pull the diff cover and check for debris. Diff cover will pull with the 1/4" allen wrench.



If you are running a Detroit locker you can use a 3/8" solid rod and drive the axle out from the opposite side.



With the broken shaft out, The spring for the inner seal was wrapped tightly around the end of the shaft. So I have to pull the ring, pinion, and locker. WHen you pull the carrier bolts BE SURE to keep them on their exact side and orientation. Meaning they are side and orientation specific. YOU DO NOT want to mix them up from side to side or flip them over. They need to be put back on in EXACTLY the same place and orientation.




You will need a pry bar or slide hammer to get them out, and an extra set of hands as they are heavy.





Stay tuned next week for rebuild.
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post #3 of 23 (permalink) Old 01-20-2013, 08:48 PM Thread Starter
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Re: Dana 60 Teardown - step by step

You would think since Yukon makes the 4340's and the Super Joints that they would work flawlessly right out of the package. That is not the case so this post will be dedicated to the installation of Super Joints into the Yukon 4340 chromoly axle. There are several videos on this if you googled it so I won't get into too much detail. What you really need know is, the videos you see make this look like a little/ very minor filing to the axle and its simple. That is not the case. You will need to file the axle very good. I was told Yukon is aware of these issues and filing/grinding will not void the warranty on the axles.

Step one is to file the flanges on the axles very good every surface the joint will contact. While you need to do a lot of filing you want to be careful not to take the hole in the flange out of round or gouge it in places.




Next step is installing the joint into your axle. Once it's in you'll need to put the clips on.


Now the joint is in one axle: grease the caps, grease the O rings you'll install in the caps, and grease the hole in the axle flange.




Now stick the caps on being careful the O ring stays seated. For this you'll need to make sure the joint is pushed out towards your cap as far as possible.



Keeping the cap level, hit the cap down onto the joint. Be sure you strike flush with the hammer. You don't want to damage the threads for the grease zerk, and clip caps to joint (pic below).


Now repeat the process to combine your inner and outer axles.




Clips


Finish by installing grease zerks and greasing joints.



Now that it is all assembled, work the axle to ensure it moves freely on the joints. If it feels stiff give it a few taps with the hammer on the axle flanges and continue to work.
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post #4 of 23 (permalink) Old 01-20-2013, 08:49 PM Thread Starter
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Re: Dana 60 Teardown - step by step

Now that your axles are assembled and ready for install you'll need to prep the housing. This includes replacing the seals and re-installing the ring/pinion/locker.

Inner Seals


You'll need a hand this guy is heavy.


This is important from the teardown. Hopefully you kept track of the carry bolts as I noted in the teardown above. Put them back on and torq them. I'm not sure what factory spec is but I did 90 lbs.


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Re: Dana 60 Teardown - step by step

Now that your axles are assembled I will dedicate this post to clearance for the knuckle. Again, you would think with Yukon being such a successful company this would not be an issue, but it is so I will address it here. (i'm not sure this is the case on all makes, and axles but the Chevy 60 will need this).

Slide the assemble axle into the knuckle and you will notice the axles will not fit.

I chose to grind the ear on the axle down to resolve this (I understand some people grind out the knuckle to make it a "one time fix", keep any negative comments to your own DIY). All it takes is some light rounding of the edges on the axles.




The ears of the axles will clear, but you will notice your grease zerk is now holding you up. You could put them in with no grease zerks, and install one at a time turning the axles later but at this point I decided to notch the knuckle.



Done axles will slide in



Now just repeat the steps from the tear down and you're rolling again.
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post #6 of 23 (permalink) Old 01-20-2013, 09:21 PM
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Dana 60 Teardown - step by step

That is some great info. Thanks for posting it. Cheers


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post #7 of 23 (permalink) Old 01-21-2013, 04:32 PM
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Re: Dana 60 Teardown - step by step

Great documentation!



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post #8 of 23 (permalink) Old 01-21-2013, 09:52 PM
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Re: Dana 60 Teardown - step by step

Great write up! Cant wait for the rest!
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post #9 of 23 (permalink) Old 01-21-2013, 09:58 PM Thread Starter
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Re: Dana 60 Teardown - step by step

Thanks everyone. I would have finished it out but I couldn't find inner axle seals. I called all the parts stores in the 4 closest towns and only found one....
I would have taken any seal but since I had to order one I went ahead and went with the Napa seal here over the national seal here. I like the guide on the napa seals better.

Anyway. Ordered them saturday and I picked them up today, but it'll be the weekend before I get back out to the shop and finish it.
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post #10 of 23 (permalink) Old 01-28-2013, 12:51 AM Thread Starter
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Re: Dana 60 Teardown - step by step

Updated and done.

Big thanks to my mom for taking all the photos you see above. She did a great job. Also thanks to my dad and gene for the helping hands along the way.
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