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Old 06-29-2006, 08:22 PM   #1 (permalink)
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Dana 60 hub disassembly guide

I am currently rebuilding a front Ford (HP) Dana 60 out of a 1990 F-350 with lockout hubs. I am not very familiar with hubs and their disassembly (I currently have an HP D30).

I need to get the hubs off so I can pull the rotors and replace them, but I don't really know how to disassemble the hubs. I got the hub off (by taking off the 6 or 7 hex bolts). There is a gear (I assume to engage/disengage the front axle) that I pulled out and a spring behind that that I got out too....but I am not sure where to go from there and I don't want to screw something up. Do I need a special tool to take a nut off at the back of the hub that will allow me to pull it apart?

What I am really looking for is a link to directions that will walk me through it step by step. I can't search here and I couldn't find anything very useful on Google. If you have a link or good directions, please post it up!

Thanks!
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Old 06-29-2006, 09:04 PM   #2 (permalink)
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Have you looked at the TECH page?
http://www.pirate4x4.com/tech/

The D60 bible by Billavista?
http://www.pirate4x4.com/tech/billav...ont/index.html
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Old 07-02-2006, 12:15 PM   #3 (permalink)
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Thanks for the links guidolyons. I found an article in the Tech section that helped a lot. I got a little closer to getting it apart, but I ran into another part that I can't seem to figure out. In the article (http://www.pirate4x4.com/tech/billav...ine/index.html) there are step-by-step instructions on how to disassemble the hub/rotor. I was able to follow most of it, but there is a section (starting with the 4th pic) that is totally different than my axle (1990 Ford). My axle looks totally different than the one he is working on, so I am having a hard time figuring it out.

I am currently at this stage:



This is not a pic of my axle; I found it in the D60 bible, but this is exactly what mine looks like right now. I need to get the three lock washers out, but I don't know how. There is a little cut-out in the out-side most washer, but no matter what I do with it, it wont move.

Does anyone have any pics of this being done or can walk me through it? Or better yet, does anyone have a link to a complete teardown of a FORD HP front D60? I have searched a lot, but all I come up with are Chevy articles.

Thanks guys!
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Old 07-02-2006, 01:24 PM   #4 (permalink)
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If you are in fact at "that stage" then you need a special socket (or a chisel & hammer) to remove the locknuts that you see in the pic. They are standard thread, the first one comes off, then you remove a retainer (easiest with a pair of small magnets, one on each side) then you unscrew the inner locknut the same way. Make sure you are looking at the correct stuff. They did use different styles of locknuts over the years... but also be aware - if you haven't removed the hub guts yet, then that would explain why it looks different than the picture. The hub guts are retained by a small thin lock ring that fits in a groove near the edge of the hub casting. If there is grease in there you may very well be missing it. It needs to be pried out with 2 small screwdrivers and is generally a pain in the neck to remove unless you've done a few and have the system down. There is most likely also a snap-ring on the stub shaft that needs to be removed before the hub guts can be pulled out by screwing 2 of the cap retaining screws into the holes and pulling. Hope this makes sense, it's the best I can do without pictures.

Hans
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Last edited by HsOffRoad; 07-02-2006 at 01:32 PM.
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Old 07-02-2006, 01:43 PM   #5 (permalink)
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This is the socket,your ford dealer can cross reference you year to a part number for the cocket.I used the instructions hub instalation instructions for a guide when I did mine.
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Old 07-02-2006, 11:17 PM   #6 (permalink)
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Yep. Need a Ford dana 60 socket. Different than the Chev/dodge ones (bastards.....found that out too late). Take off the first nut, then a washer comes out, then there is a second nut. From there the whole hub/rotor assembly will slide off the spindle as one piece.

Yes you can supstitute a hammer and chisle for the special socket. Just drive it into the edge of the nut to make it turn. It's slower but it works. Mine had to go this route.
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Old 07-03-2006, 05:43 PM   #7 (permalink)
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Thanks for the helps guys, I am going to pick up the socket tomorrow.

HsOffRoad: You did a very good job explaining how to get the guts out. I had already gotten them out, but I would have been able to follow your directions. You're right; getting the big snap ring out takes patients and is a PITA!

Brokejeep: Thanks for the pic; now I'll know what I am looking for!

Does NAPA or other auto parts stores carry the socket? Or do I have to get it from a Ford dealer?

Thanks
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Last edited by BFJ93YJ; 07-03-2006 at 05:44 PM.
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