. Tighten the nuts to specified torque. If they are nice they may even do it for free. To the left is the Dana 60 with hubs, spindles and axle shafts removed. Axle positioned under truck, u-bolts finger tight, looking good! If you think you may want to reuse or sell the axle than follow the procedure in the Haynes manual, which is to remove one half at a time. You must also check the driveshaft to transmission cross member clearance.
I am going to try it out without the sway bar and decide if it is needed. If you do this you are more than likely to have the alignment close to spec. Attempts with a wimpy 2 jaw puller will require removal of the gear box, and probably a broken vise or stripped puller… its much easier with the right tool. Before you start A complete rebuild of the Dana 60 is recommended, however if the gear ratio is what you need and you do not plan to run a Detroit locker the rebuild process is greatly simplified. Straight axles can be aligned by the home mechanic, with the weight of the vehicle on the wheels, put a small pin to hook your tape measure too in each front tire, at the front of the tire, measure the distance between the pins, roll the truck backwards, until the pins are 180 degrees from the first measurement. Once you have the driveshaft installed your done, if you rebuilt the front diff make sure to follow the break in procedure or all your hard work will be ruined.
You may wish to grind down the rivets and remove the bracket altogether, however we felt it best to leave it in place and grind down the part that would interfere with the Dana 60, see the following pictures. A — The bracket as viewed from the drivers side, after being ground down. Measure how far they protrude from the bottom of the leaf, then measure the distance from the spring pad to axle housing on the Dana 60, through the hole where the center bolt goes. A good hard landing and the driveshaft may meet the cross member. The solution to all the problems: a locked, 4. At this time also note the clearance between the driveshaft and the transmission cross member with all the weight of the vehicle off the front wheels. Now measure the distance between the pins, this will give you the amount of toe in or toe out.
Click image for larger view. I had to have mine shortened one inch. Alternatively if you remove the steering box with pitman arm attached you can take it down to your local Ford dealer and ask one of the mechanics to impact it off they have a special tool , for 10 bucks or so. It also appears to provide structural support to the engine mount. Place the Dana 60 on a jack and position it under the springs. B rivets holding bracket to frame cross member.
I did not get the sway bar and sway bar brackets when I purchased the Dana 60, if you did now is a good time to install them. We found that the yoke on the Dana 60 was an inch further back than the yoke on the Dana 50, requiring the drive shaft to be shortened one inch. Now compress the springs as much as possible, note the travel of the driveshaft. If you choose to replace any of the tie rods make sure to count the number of turns when removing the old rods, and put the new rods in with the same amount of turns. The spacer was placed between the mount and cross member with a coating of never seize to prevent corrosion. You can then loosen off the tie rod sleeve and rotate the sleeve the desired amount to adjust the toe in.
If the driveshaft is too long it could jam into the transfer case causing major damage. Once the axle is firmly in place put the axles back in and assemble the spindles and hubs. However you may notice something odd with the rear to front track. My F-250 only has the little 302, we figured that I probably wont see much body roll given how stiff the front springs are. Actually I did but only with generous amounts of throttle.
Procedure First a donor vehicle with a Dana 60 must be found, look for 1986 and up F-350 trucks, see background for more information. A third, on the drivers side, is riveted and bolted to the frame near the engine mount. Next you may need to grind down the leaf spring center bolts. Compare the numbers with those measured with the old axle. With the vehicle weight on front wheels on ground disconnect the drive shaft at the diff and measure how much the drive shaft compresses relative to the axle pinion yoke.
Before removing the old differential jack the truck up so that there is no weight on the front wheels, note the amount of travel of the front driveshaft. Canadian Tire loans the tool in Canada. You may need to remove the steering box to do this, but if using the proper tool you should be able to do it on the truck. There were two brackets which unbolted and came off with no problems. Some auto parts stores will rent or loan Lisle loan a tool a pitman arm puller. .
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