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Dana 60 kingpin removal. The easy way.

72K views 98 replies 67 participants last post by  rockyota83  
#1 ·
Okay, I thought I would post this and pics to let everyone know what I have determinded to be the easiest way to remove a Dana 60 kingpin without a cutting torch, any kind of heat or 8 foot cheater bars.
(This one I owe to JMHinesCJ, it was his idea).

During this process, I tried 7 feet of cheater on my 3/4" breaker bar and broke the breaker bar. I also snapped my 7/8" x 9/16" acorn lug nut in half.
I didn't have access to a cutting torch for heat, so I drilled a 1/2" x 1/2" hole in the bottom side of the kingpin and filled it with weld to get it red hot.
Broke the lugnut after that.

So here is what works:
-Get a 4 inch angle grinder and a very thin cutting disc. Cut a deep groove all the way around the kingpin that goes to the shank. Make cut ALMOST to the underside of the kingpin head where the kingpin touches the C (see pic)
Once cut is made (about 3/8" deep), take lug nut, insert in kingpin, put 3/4 inch ratchet and 7/8" socket on it and give a small tug. It will break loose.
Total time takes about 3 minutes per kingpin.
No heat, no broken tools.
Good luck!
 

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#2 ·
I prefer the 2" square tube method only because I hate angle grinders with a passion.

Favorite 2" square tube. Favorite welder. Favorite pipe wrench.

Welding the pipe to the kingpin gets it hot enough. Walked it off like it wasn't even torqued.

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This was after splitting the kingpin with the nut and bolt trick and every other home remedy.
 
#12 ·
Can't find any crazy hex stock, don't want to use a lugnut or whatever?

Many cold chisels are 7/8" HARD hex stock. Chopsaw to length and tack into a 7/8 socket. The whole shebang should cost less than $5 and you should still have some chisel for cutting/driving stuff out.

If it's REAL stubborn, weld the hex stock to the kingpin and the heat should free it up so you can do the above cutoff wheel trick or continue with long cheater pipes. If the hex gets welded, grind off tack and cutoff some more from the chisel and tack it into the socket for the other side.

Worked great on my RUSTY, sitting in a field shiat.
 
#14 ·
i made the really big hex allen and heat, with a cheater bar as well, bent it :mad3: and then said screw loaded up the axle went to the les schwab tire store that a freind of mine works at. and he used one of those trucker impacts that are almost the size of a jack hammer and it pulled them right off and then put the new ones right back in took all of about 25 minutes with the drive time of twenty minutes. which really sucks considering i spent an hour and a half on them the night before.:shaking:
 
#15 ·
so a pipe wrench around the base of the kingpin, heat and a big fawkin cheater? I feel like a stupid fawker, I had a 1/2 breaker bar and like 4 foot of cheater. i think that kingpin is still laughing at me. When I pulled the driver side apart there was some funky little thing sitting in the kinpin. I didint have one in the other side and I didnt see it with the rebuild kits or anything. It looks like a castle nut on both sides, I am not sure what it is. May be part of it though, any know?
 
#17 · (Edited)
What has always worked for me is just a 1 ton lug nut. fits right in the hole.

Then bring out my big impct gun and wamo!! done..

I have front and rear strear they all came out this way when they laughed at a BIG pipe wrench...:cool2:
 
#48 ·
Not enough heat on the knuckle. If so, there wouldn't be any grease left!

I heat the shit out of them and then go away for an hour, come back and twist them out with a 1/2" ratchet and lugnut. Life is too short to fuck around. :grinpimp:
 
#25 ·
I turn the axle over with the thread end exposed. I take and heat the the king pin inside the hex area and use candle wax or para-fin wax on the thread in end. The heat draws in the wax... let cool and flip over take my 7/8 hex socket from proto and my titanium 1/2 impact and wallah it is out.
 
#31 ·
I just use an 80 dollar snap on 7/8 hex impact socket, and my $400 ingersol rand 3/4" impact from work. The impact i kind of have to have anyway so no biggie, i was kind of mad about buying the socket, but then i realized it comes in handy for a lot of things, i use it a lot as a spacer to press bearings and such. If i break it, eh, fuck it, it's snap-on, they warrenty it.
 
#33 ·
git er done!
I'll show you the easy way!
I used a 7/8" allen wrench, split the head wide open
tried a 24" pipe wrench and a 10' pipe it thretened to fall off the jackstand...
Then I got a brilliant Idea!!!
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use a 1 1/2 ton comalong with a sling thru the eye of the comalong handle to a hook on the bumper! aprox. 3 foot TONS! popped it like it was nothing.
3 foot tons = 6000 ft/lbs (aprox) I have lifted 3 tons with a 1 1/2 ton comalong
(not recomended)

Enjoy!
 
#38 ·
I got pissed when I fawked the kp up and couldnt grip it well with a pipe wrench, so I welded the fawkin pipe wrench to the king pin. 6foot of cheater and I pulled that bastard off. I think ground off the welds and still use the pipe wrench today. It is bent to fawk though :laughing:
 
#39 ·
the setup my buddies have used was always pretty simple.

had a few 19" x3/4" grade 8 bolts laying around, heated one up and bent it into and "L" then ground the hex part down from 1 1/8, to 7/8's. Hammer into king pin, slide on 6 foot pipe, and BANG kingpin breaks free.