Jana 76 & 54

[unRL]

Yes you can fit Dana 70 gears into a Dana 60. It requires an install kit, some grinding, a D70 carrier (high or low speed) or a modified D60 carrier. You can also fit Dana 50 gears into a D44 (hp of course). The JANA 54 uses a high speed D44 carrier.





UPDATE Feb 21 2011
This thread started it all and became rather long and covers many hybrids and theory: If you have found this thread you will be very interested in these threads which deal with each hybrid specifically;
more info on each aspect of these upgrades can be found on the following specific threads:

HOW TO Install
D50s into HPD44's, Jana 54:http://pirate4x4.com/forum/showthread.php?t=948996
8.9" JK 44s into LP44s, Jana K4:http://pirate4x4.com/forum/showthread.php?t=957491
D70s into D60s, Jana 76:http://pirate4x4.com/forum/showthread.php?t=946421
D80s into D70's Jana 87: http://pirate4x4.com/forum/showthread.php?t=958266
Holding it all together, Jana cover girdles:http://pirate4x4.com/forum/showthread.php?t=958047

[spidr]

Cost on the kit?

[boardbysled]

Yes, very interested in the price. On the Jana 54 specifically. This may allow me to keep my 44 for what I want to do...

[unRL]

Still working this out a bit. I want to provide 2-3 stages of kits, and would look for your info on what you need.
Stage 1, bare bones aprox. retail $175, assumes you have a collection of good parts already, bearings & shims. so all you need is my adapter bearings.
Stage 2, standard kit, $200.00 Comes with addapter bearings, shims, seals, extra nuts bolts. Install tool.
Stage 3 comes aprox retail. $250. with every thing you need if starting with a bare housing.

[Blase]

In the pictures.

That is a Dana 44 with Dana 50 gears and carrier in it?

Why the studs for the caps instead of bolts?

And why do they come through the cover?

I like the idea and i'm not bashing at all. Just looking for some tech.

[unRL]

This is the 54 install, the 76 is similar

[boardbysled]

How much would you charge for an Install?

Also, did Dana 50's ever come in Low pinion? As in, could you install some LP 50 gears into a LP 44?

[dan58]

Have you tried putting the 70 gears in an aftermarket housing such as the Currie RJ?

[unRL]

Originally Posted by Blase

In the pictures.

That is a Dana 44 with Dana 50 gears and carrier in it?

Why the studs for the caps instead of bolts?

And why do they come through the cover?

I like the idea and i'm not bashing at all. Just looking for some tech.

Glad you asked, 1st off that is a pic of the Jana 76 cover. I've had this idea for a Carrier cap bolt girdle for some time and decided to implement it now. I got the idea from a 28 Studebaker rear end. (they were way ahead of their time) Its built like a 9" drop out but still it had a rear cover with factory studs through it for support. I've also seen thick Aluminum cast covers with a jamb bolt to support the bearing cap in the middle. After breaking 4 sets of ring & pinions in my rear 60 I could see that the carrier bearing caps had movement in them that could be detected by a close inspection of the mating surfaces. So this cover incorporates both Ideas, jamb bolt and stud girdle. Also note the bulge in the cover put in to clear the larger ring D70 gear, Note this is necessary for the Jana 76 but not required for the Jana 54.
The stud girdle cover is not required for the install but the better you can keep things from moving around the longer the gears are going to last. I suppose I can make these an option for those that want it.

[unRL]

Originally Posted by Blase

In the pictures.

That is a Dana 44 with Dana 50 gears and carrier in it?

That is a DANA44 with Dana 50 gears and a Dana 44 high speed carrier in it.

[unRL]

Originally Posted by boardbysled

How much would you charge for an Install?

Also, did Dana 50's ever come in Low pinion? As in, could you install some LP 50 gears into a LP 44?

I could retire is LP 50 gear were available, but they are not.

[unRL]

Originally Posted by dan58

Have you tried putting the 70 gears in an aftermarket housing such as the Currie RJ?

Not yet, the only Hi pinion D70 gear available that I have found are 5.13s, and will be doing them soon in a standard D60 Rev housing. I see no reason that it would not work in an after market unit, probably require a bit more grinding. Note castings vary, I done some installs that required almost no grinding at all, and others that took quite a bit.

[boardbysled]

How long have you been running your kit?

What kinda power is your motor putting out?

Would these work on a rig that is driven on the highway?

[RufftyTuffty]

Originally Posted by unRL

Not yet, the only Hi pinion D70 gear available that I have found are 5.13s, and will be doing them soon in a standard D60 Rev housing. I see no reason that it would not work in an after market unit, probably require a bit more grinding. Note castings vary, I done some installs that required almost no grinding at all, and others that took quite a bit.

This is the problem...most of the aftermarket housing are designed tighter...i only have 3/16" or less clearance each side but i'll need 3/8" for you kit.

It seems that OEM housings offer a bit more room.

~Mike

[unRL]

Originally Posted by boardbysled

How much would you charge for an Install?

I figure it takes about 2-3 hours longer than a standard ring & pinion set up. The last Front end I did with an air locker took 11 hours. I charge $80 per hour, plus the cost of the kit. For exact quotes please email me at carl@jantzengineering.com.

[unRL]

Originally Posted by boardbysled

How long have you been running your kit?

What kinda power is your motor putting out?

Would these work on a rig that is driven on the highway?

I have about 400 hp, with 131 to 1 low gear. & 47 tires. No problemo, These work well on the highway, I do not reduce the bearing contact area at all on either the pinion bearings or carrier bearings.

[redneckengineered]

This is badass and the cost is a no brainer if you're blowing up 60 gearsets. Thanks for the tech and R&D to bring this out.

[unRL]

Originally Posted by RufftyTuffty

This is the problem...most of the aftermarket housing are designed tighter...i only have 3/16" or less clearance each side but i'll need 3/8" for you kit.

It seems that OEM housings offer a bit more room.

~Mike

I don't see a problem aftermarket, as you could do your grinding, then weld a piece of 3/16" or 1/4" to the outside of the housing. The one housing I did with all the grinding got down to about 1/8" thick in one area about the size of a quarter, so I just did a small weld build up in that area. Please see instructions, which I'm trying to upload now but Pirate does not like my file type.

[Blase]

Originally Posted by unRL

Not yet, the only Hi pinion D70 gear available that I have found are 5.13s, and will be doing them soon in a standard D60 Rev housing. I see no reason that it would not work in an after market unit, probably require a bit more grinding. Note castings vary, I done some installs that required almost no grinding at all, and others that took quite a bit.

I would be very interested in this. HP 60 rears are scary.

What carrier do you expect you would have to use?

If the Dana 60 HP carrier/locker could be reused I bet you'd have guys lined up for a kit!!

Heck even a cover to stop deflection would be pretty popular i'd imagine.

[varsis]

Originally Posted by unRL

I don't see a problem aftermarket, as you could do your grinding, then weld a piece of 3/16" or 1/4" to the outside of the housing. The one housing I did with all the grinding got down to about 1/8" thick in one area about the size of a quarter, Attachment 545990so I just did a small weld build up in that area. Please see instructions, which I'm trying to upload now but Pirate does not like my file type.

hmmm what about grinding the ring gear down instead of the housing? I think that would give you the extra clearance needed in a smaller housing. I like the idea though 70 gears in a 60 housing. Smaller pumkin than a 14 bolt but the same strength in the ring gears or close. Too bad my rear housing is bent doh.

[unRL]

Originally Posted by varsis

hmmm what about grinding the ring gear down instead of the housing? I think that would give you the extra clearance needed in a smaller housing. I like the idea though 70 gears in a 60 housing. Smaller pumkin than a 14 bolt but the same strength in the ring gears or close. Too bad my rear housing is bent doh.

This whole system splits a lot of hairs to work, yes grinding the ring gear down a bit would work, I'd say 1/8" max.

[unRL]

OK so I'm trying to get my install instructions uploaded to this thread. It is in a 13 page word file with nice pics and everything. (This will also be on my web site soon but my web guy is a bit behind), so any tips on how to up load it here would be of great help Thanks!! I guess I could cut and paste the wording and then the pics but then the layout will be confusing.

[unRL]

JANA 76
To begin with this installation is not suggested to be done by a 1st time Ring and pinion Installer. I would suggest a minimum of 4 ring & pinion set-ups experience prior to doing this modification. This kit is designed to be installed without machine work if all the proper parts are purchased. Good metal fabrication skills are a must. If you do not have a collection of bearing pullers, drivers, grinders, micrometers, dummy bearings, press, torch, welder, vice etc. you probably should not be doing this job.
NOTE: This is just not one of those “do-it late Friday night to go wheeling Saturday morning jobs”. This Kit is designed to work with Stock Dana 60 standard housings and Dana 70, & 70U standard parts. Other manufactures’ parts may require machine work. Also if you are used to doing a set up in 3-4 hours, then plan double or triple time.
I as much as you, hate instructions that are either too detailed or not detailed enough. Generally I want to see a good picture and the basics and I’ll get right to it; however there are some steps in this conversion that must be done in the correct order or bearings and seals will be permanently destroyed. Now, I know you don’t want to review 16 pages of procedures to find two torque specs and a couple of critical dimensions. So I will provide a Three step set of instructions, 1st I will give an overview of operations, 2nd detail it all, and the reasons things are done in such order & some hints, and 3rd a check list so you can go along and not paint yourself in a corner, or more importantly discover you have to grind something and the only way to prevent getting grit into your new bearings & locker will be to completely disassemble the unit wasting hours of rework & clean up time.
OVERVIEW
The basic order of operations will be to:
(1) Grinding the housing for ring gear clearance.
(2) Grind the carrier bearing snout to clear a narrower bearing.
(3) Differential cover reforming and clean up.
(4) Partial pinion set up, Installing adapter bearings, & spacers, no seal
(5) Carrier & ring gear set up, with adapter bearings & spacer
(6) Gear pattern and carrier bearing preloads
(7) Pinion preload setting
(8) Seal and seal ring, with final install of pinion with seal
(9) Ring gear final install
(10) Install cover oil, etc.
(11) Break-in

[unRL]

DETAILED INSTRUCTIONS
(1) Grinding the housing
a. After removing all old D60 parts reinstall just the d60 ring gear on the D60 carrier with just 4 bolts, and reinstall.
Note: If you are going lower gears you can put washers between your carrier and your old ring gear to simulate the thickness of your new gear, and you can also add an 1/8” thick lock washer to simulate a low speed carrier if your carrier is high speed.
Hints: At this point I can’t emphasize enough that having a set of dummy carrier bearings will save an immense amount of time, energy, and frustration.
b. If you don’t have dummy bearings a set can be made out of your old bearings by sanding or honing the insides out until the bearings glide on and off of the carrier bearing snouts. Glide means that you can slip it on and off by hand, but it would not fall off under its own weight, thus there is no clearance or play when slipped on. This can also be done with a hardware store flap wheel sander in a drill. I usually sand around evenly for a minute and then check for fit, repeating this step 3 to 10 or more times until I get the perfect slip fit. If your old bearings are worn a few thousands or are slightly different dimensionally you can adjust later with the new bearings and shims, at least you will be very close as you move towards final assembly.
Note: When using dummy bearings pull out a .010” shim from each side of the carrier, this removes preload making the carrier easy to take in and out.
c. Place the D60 carrier assembly into the housing. You will notice that there is about ¼” space all around it. Since the D70 gear is ¾” larger in diameter you need 3/8” space all around it. Thus you will be grinding approximately 1/8” into the housing. The housing will clear the larger ring gear most the way around except at the very top, bottom, and front near pinion head bearing.
d. Using the supplied 3/8” ball on a stick feeler gauge, dip it in gear marking compound, grease or paint then place it on the outside of the ring gear and it will leave a trail where you need to grind for top and bottom clearance. Then since you won’t be able to exactly see what you need at the front, mark out each side of the ring gear, you will grind the housing down between these marks until the chamfer is gone for the pinion bearing, and about half of the cast in oil scraper.

[Corey Young]

Dana 70B and Dana 70HD have different carrier widths, will both carriers fit in a Dana 60 housing?