I have finally completed my first MAJOR surgery of my TJ, a complete rebuild and swap of a 1970 dana 60.

Here's some pictures. (Mostly of work in progress). I picked up my cut driveline this morning and everything appears fully operational. The one thing that I would like to do is re-bend and protect my brake lines (had to re-route a couple times). Overall I think I lost about 1/4" clearance after plating the dana 60 vs dana 35.

Anyway here you go:

http://home.insight.rr.com/rpark/Dana35Clearance.JPG
http://home.insight.rr.com/rpark/Removed.JPG
http://home.insight.rr.com/rpark/DanaComparison.JPG
http://home.insight.rr.com/rpark/Beadlock.JPG
http://home.insight.rr.com/rpark/Dana60.JPG
http://home.insight.rr.com/rpark/Partiallybolted.JPG
http://home.insight.rr.com/rpark/Driverside.JPG
http://home.insight.rr.com/rpark/Passside.JPG
http://home.insight.rr.com/rpark/Dana60Clearance.JPG

It's a 32 year old axle housing converted to disc brakes, shaved housing, new bearings, new ring (shaved) & pinion, rattle can painted, rubicon express brackets, full width 65" wms, miller locked.

Bob

To do list:
1) Re-bend brake lines
2) Wheel the s$%t out of it.
3) Go shopping for a front axle
4) Consider buying aftermarket sway bar (stock one won't fit) because no front or rear feels awful springy.

so...5 lug front, 8 lug rear??
35 spline shafts?

Yes I'm running the stock 5 lug dana 30 up front (it'll give me inspiration to complete a front swap a little quicker). For now I'll carry a 5 lug spare and excert the extra effort to dismount it from the 5 lug wheel to mount on the 8 lug beadlock if it becomes necessary.

I stayed with 30 spline shafts because I've got 4 tired hampsters that only put out a bakers dozen of ft lbs of torque (I've got plans for an engine/tranny/transfer case swap hopefully next winter). My spindle ends (1970 International truck) were not large enough to bore out to fit the 1.5" shafts, and I didn't feel I had the expertise to replace the spindles.

what size are your wheels, back spacing, & tires? I've got the same thing being put together in the shop right now and I'm debating on narrowing it at all, I planned on keeping it wider than stock but yours doesn't look to wide so I might go that route.

Gonna have that damn 8 lug rear, 5 lug front for a month or 2 also.

I've got 15"x8" wheels w/rockstomper beadlocks (so effectively they are 15x10) with 3" backspacing with 35's mounted. I only had to grind a very small portion of the calipers to make them fit (5-10 minutes per side). I have the stock TJ flares as well, so if you have any extended flares 6-7" it would look even better.

Total cost?

Paul

Originally posted by nasvik
Total cost?

Paul

Axle from 1970 International 1200D 3/4 ton pickup truck - from a pick & pull yard ($50).
Disc brakes and custom caliper bracket ($250)
New wheel bearings & seals ($110)
Rubicon express brackets ($225)
Cut and balance driveshaft ($30)
Spray paint and primer($20-30)
4.88 ring & pinion from Ebay ($100)
Shave ring gear ($50)
Cut/plate pig (couple welding sticks)
Custom diff cover protection (free)
Miscellanous nuts bolts etc. ($30)
Miller locker (free).

Grand Total $875

It has been offset by selling my old spares ($400) and my yet to be listed dana 35. In the end it will have cost me my time, which was pretty significant, but a great learning process.

4) Consider buying aftermarket sway bar (stock one won't fit) because no front or rear feels awful springy.

You don't even need the rear sway bar. I have the same set up in the rear of my TJ but w/o disk breaks, and I have not had a rear sway bar for about a year now. I could not tell the difference.

Originally posted by Drunk Guy


You don't even need the rear sway bar. I have the same set up in the rear of my TJ but w/o disk breaks, and I have not had a rear sway bar for about a year now. I could not tell the difference.

I am missing both the front and rear sway bar. Do you have your front sway bar hooked up on the road? I couldn't tell much of a difference with one disconnected. It's a little more noticeable without either sway bar. I'm going to drive it for a while and evaluate it.

I have just the front sway bar on mine and it's just fine, a little body roll but nothing to be concerned with, actually the rear squats so well without the rear sway bar I can easily pull a front tire off the ground when making a gentle turn from a stand still....when the front is discoed then their is major body roll, makes it more fun driving around town, but off road it does quite a bit better

and extended fender flares just make for bigger targets when getting close to trees, rocks, and such......on the list of what I need/want to make is tube fender flares

where did you buy your axle brackets for $225? The lowest i have seen is 280 for the rear and 380 for the front. Thanks

What are you going to run up front when you get the chance?

Whatdaphuk- RE dealers don't like to advertise their prices. I'll PM you with the email or # for two dealers that can help you out.

Military Jeeper- I would absolutely love to strike gold and find a Ford HP 60 for a reasonable price. But I haven't started the hunt yet, it really depends on width, price, amount of work, etc. I haven't really decided on my criteria yet, but I will soon. My preference would be any type of 60 up front. But I may settle for a 44 and upgrade to CTM joints.

Bob

you could try to find a 44 off an older bronco and fab mounts to use the factory radius arms. THat way you wont have to spend too much extra money and still get good flex/ride.

TJBob....how bout letting us know about the braking system? Did you change the M/C? What rear calipers did you use on what width disc? It looks way better than any 35.....

Originally posted by Chark
TJBob....how bout letting us know about the braking system? Did you change the M/C? What rear calipers did you use on what width disc? It looks way better than any 35.....

I used this guy's site Mopar Mudder (http://www.moparmudder.com/brakes.htm) as a guideline. I had to modify several steps and the template, but it give the jist of it on his site.

Bob