My DIY 2005 Dodge Dually 4x4 5.9L free-spin kit - Pirate4x4.Com : 4x4 and Off-Road Forum
 
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Old 04-14-2010, 07:24 AM   #1 (permalink)
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My DIY 2005 Dodge Dually 4x4 5.9L free-spin kit

So I've been wanting to do a free-spin kit for quite a while now, ever since I started worrying about losing a unit bearing in the middle of nowhere while towing. I had replace my ball joints at 85K, and now at 135k they needed replacing again. So how to do a free-spin setup and fix the ball joint issue at the same time? Being a dually makes it a little more expensive and involved as several of the manufacturers don't sell a dually kit, you have to do a single wheel kit and then spend $400-500 more on wheel spacers. Then you add the rebuildable/more durable ball joints and you're in the $2500-$2800 range all said and done.
So I came up with the idea of using a kingpin Setup off of a Dana 60 axle, sounds good right? After going over it in my head and taking measurement after measurement I came up with the resolution that it should work out fine.
I sourced a 79 Chevy Dually Dana 60 from a friend who just wanted the center section and tubes for his project, $200 for everything from the inner "C" out. I then purchased yukon 35spline stubs, warn premiums, 5-806 spicer joints, spindle rebuild kit (bearing, seal, etc), new loaded calipers, kept the old bearings but they are in excellent shape, kept the old rotors, chevy and ford tie-rods. The kingpin cones were good, and I was given a camber adjuster kit from my buddy Jake.
Step 1 was to have the inner "C" of the knuckles bored out to 3.503 to go over the dodge tubes which are 3.500
STep 2 The axle shafts proved to be easier than I expected. The diameter of the AAM u-joints is identicle to the diameter of the 5-806x joints. the width of the yoke is just a little narrower on the AAM inner shaft so there is no groove on the joint cap for the circle clips so I tacked the caps in on the inner shafts and used full circle clip on the yukon shafts.
Step 3 I cut the inner C's off the AAM tube (who'd want them anyway) gound off the weld the rest of the way and tapped on the new D60 inner C's. I set the caster at 5*. I then assembled the whole side to get the depth correct for side to side throw of the axle shaft when turning. It turned out that the inner C needs to be out about .250 from flush unlike the AAM C's which were flush. But, that enabled me to get a nice flush weld on the tube end for added strength since the C's are not pressed on.
Step 4 Weld it all up
Step 5 Assembly including brake lines which work fine just need to source chevy banjo bolts as the AAM are fine threaded.
Step 6 cut chevy tie-rod and lengthen 5.125" for wider stance of the dodge.I cut about 8 inches off the dodge drag link and added on 8 or so inches of a ford tie rod end. I had to ream out the steering stabilizer hole on the chevy tie-rod which would now be the drag link mounting hole. Two tabs on the tie-rod and the stabilizer is good to go.
Step 7 I set camber at plumb on the passenger side and out on the top a degree or so on the driver side to avoid wander. I set the tow in at about 3/16 in 3ft.
Step 8 Paint
Step 9 Drive and I couldn't be happier. It tracks true, and after a little adjustment my steering wheel is even straight
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05 Dodge free-spin conversion /forum/dodge/880388-my-diy-2005-dodge-dually-4x4-5-9l-free-spin-kit.html
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LS motors are like tampons....every VAG has one!

Last edited by wheelin66bronco; 04-28-2010 at 01:33 PM. Reason: meant camber, not caster in step 7
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Old 04-14-2010, 07:26 AM   #2 (permalink)
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05 Dodge free-spin conversion http://www.pirate4x4.com/forum/showthread.php?t=880388
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LS motors are like tampons....every VAG has one!
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Old 04-14-2010, 07:27 AM   #3 (permalink)
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05 Dodge free-spin conversion http://www.pirate4x4.com/forum/showthread.php?t=880388
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LS motors are like tampons....every VAG has one!
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Old 04-14-2010, 07:28 AM   #4 (permalink)
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05 Dodge free-spin conversion http://www.pirate4x4.com/forum/showthread.php?t=880388
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Originally Posted by broncolou View Post
LS motors are like tampons....every VAG has one!
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Old 04-14-2010, 07:31 AM   #5 (permalink)
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05 Dodge free-spin conversion http://www.pirate4x4.com/forum/showthread.php?t=880388
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Originally Posted by broncolou View Post
LS motors are like tampons....every VAG has one!
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Old 04-14-2010, 07:33 AM   #6 (permalink)
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05 Dodge free-spin conversion http://www.pirate4x4.com/forum/showthread.php?t=880388
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Originally Posted by broncolou View Post
LS motors are like tampons....every VAG has one!
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Old 04-14-2010, 07:34 AM   #7 (permalink)
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05 Dodge free-spin conversion http://www.pirate4x4.com/forum/showthread.php?t=880388
Quote:
Originally Posted by broncolou View Post
LS motors are like tampons....every VAG has one!
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Old 04-14-2010, 07:35 AM   #8 (permalink)
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I've been driving for 3 days now, all good.
Thanks to Chris at Nukeproof for the shop space to do the project.
Now get that Damn Fodge done!!!
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05 Dodge free-spin conversion http://www.pirate4x4.com/forum/showthread.php?t=880388
Quote:
Originally Posted by broncolou View Post
LS motors are like tampons....every VAG has one!
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Old 04-14-2010, 08:09 AM   #9 (permalink)
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Awesome!

I gather that those unit bearings are ~$500 each... No thanks... Glad I've already got a Kingpin setup! ('90 W-250 CTD 5-speed)

Mike
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Old 04-14-2010, 08:12 AM   #10 (permalink)
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Outstanding job! This is a great mod.

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Old 04-14-2010, 08:13 AM   #11 (permalink)
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That's some damn nice work! So what was the total cost for this setup?
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Old 04-14-2010, 08:45 AM   #12 (permalink)
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That's some damn nice work! So what was the total cost for this setup?
Thanks! Total price came out to right around $1200 +/-. I could have saved about $400 if i'd kept the 30spline chevy stubs and hubs but I wanted the strength of the 35's.
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05 Dodge free-spin conversion http://www.pirate4x4.com/forum/showthread.php?t=880388
Quote:
Originally Posted by broncolou View Post
LS motors are like tampons....every VAG has one!
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Old 04-14-2010, 08:46 AM   #13 (permalink)
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Nice no ABS bro!
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Old 04-14-2010, 09:27 AM   #14 (permalink)
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Bad Ass Tyson! I can't believe you got it done in a weekend. Some pretty impressive shit keeps rolling out of that shop. I'll call you, but let me know if you guys want to do dinner at our place on Friday night.
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Old 04-14-2010, 01:40 PM   #15 (permalink)
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Ya nice job Tyson, and a good thread to boot!



Now get your lift on that thing.......GRANDPA!
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Old 04-14-2010, 05:50 PM   #16 (permalink)
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Nice no ABS bro!
Annndd?
Travis..
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Old 04-15-2010, 09:14 AM   #17 (permalink)
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Annndd?
Travis..
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Nice no ABS bro!
ABS was designed for people who don't know how to drive in slippery conditions, people who need their vehicle to drive for them. I just need to get the abs and brake lights out now.
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05 Dodge free-spin conversion http://www.pirate4x4.com/forum/showthread.php?t=880388
Quote:
Originally Posted by broncolou View Post
LS motors are like tampons....every VAG has one!
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Old 04-15-2010, 10:53 AM   #18 (permalink)
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Air bags and ABS are for people who can't control their vehicle and crash. Don't crash and you won't need them. I disco'd the rear ABS on my 91, it was a joke. You could modulate the pedal faster yourself than the "computer" could do it
Travis..
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Old 04-15-2010, 12:38 PM   #19 (permalink)
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Nice no ABS bro!

ABS is for pussies!


Good job on fixing the problem and making it beefier at the same time.
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Old 04-15-2010, 12:56 PM   #20 (permalink)
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I heard of too many people rearending cars on ice from the abs not letting front brakes do their work.

Now there's a new toyota invesigation because a new Lexus is having issues with the stability control letting the rear end drift when going to fast around corners."I can't drive, blame the car!"

Nice upgrade at a decent price
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Old 04-15-2010, 08:51 PM   #21 (permalink)
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Very nice work! 35's are the shizzle
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Old 04-16-2010, 11:43 PM   #22 (permalink)
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Wow, way to go! Another project to add to the list.
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Old 04-18-2010, 12:08 PM   #23 (permalink)
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how much smaller are the brakes compared to the stock brakes you took off? can you tell a difference? i would like to do something like this if i can still have great brakes
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Old 04-19-2010, 07:47 AM   #24 (permalink)
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the rotor size difference is insignificant. the D-60 is something like .25 or .5" smaller diameter. you can't tell even under a hard brake. I was wondering the the advantage/disadvantage of the single piston caliper versus 2 piston as far as clamping force and heat dissipation? I think the quality pads help more than anything
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Old 04-19-2010, 07:51 AM   #25 (permalink)
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how much smaller are the brakes compared to the stock brakes you took off? can you tell a difference? i would like to do something like this if i can still have great brakes
That was my only real concern when I came up with the idea of the swap. I tried to locate some dual piston calipers for the Chevy 60 but was unable too. I did get a lot of input on the Chevy forum as to how well the calipers will stop a 44" tire though.
The rotors are about 1/2" diameter smaller on the chevy and of course have the huge single piston caliper as opposed to the dual on the AAM. Honestly I really don't notice a change in stopping power. I haven't towed a heavy load yet, but I do use the exhaust brake for most of my braking when towing heavy. If it becomes an issue I already looked into upgrading to EBC Slotted rotors and good pads eventually.
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05 Dodge free-spin conversion http://www.pirate4x4.com/forum/showthread.php?t=880388
Quote:
Originally Posted by broncolou View Post
LS motors are like tampons....every VAG has one!
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