Tight dana 60 after rebuild - Pirate4x4.Com : 4x4 and Off-Road Forum

Lil'John · 07-30-2005, 08:40 PM

I've got an early Dodge Dana 60 that I've rebuilt. The problem is the axle shafts are VERY tight... to the point that even with vice grips on the outer shafts, I'd need a cheater to move them (and no, I did not force them)

I had the gears and ARB installed by Sean over at Rivercity Diff so I know they are in good shape as well as haivng him handle the long side shaft(shortened)

First question is what order does the spindle, brake caliper bracket, and stock brake backing plate go onto the axle? Is the spindle on the knuckle? Or would the brake backing plate go between them?

Is there something else I should be looking at?

I replaced EVERYTHING with new parts: seals, shafts(didn't have any), bearings, etc.... even the slingers that go on the outer shafts.

Any advice on where I should focus my efforts would be GREATLY appreciated. I did search and I also looked at BV's Dana 60 tech article. Sadly, the exploded diagram doesn't show the brake backing plate

mike · 07-30-2005, 08:43 PM

Cant move the shafts in and out? or cant rotate them?

edit: never mind reread it. Are the inners as hard to move?

Lil'John · 07-30-2005, 08:58 PM

I can't turn them at all if I have the spindles fully tightened to the knuckle.

If I don't have the spindles fully tightened, it is VERY easy to move.

mike · 07-30-2005, 09:01 PM

sounds like the outers ears are jamming on the spindle.

07-30-2005, 08:40 PM	#1 (permalink)
Lil'John Zeus of the Sluice Join Date: Feb 2000 Member # 278 Location: Under a N. CA carport wrenching on my FJ55 Posts: 4,565	Tight dana 60 after rebuild I've got an early Dodge Dana 60 that I've rebuilt. The problem is the axle shafts are VERY tight... to the point that even with vice grips on the outer shafts, I'd need a cheater to move them (and no, I did not force them) I had the gears and ARB installed by Sean over at Rivercity Diff so I know they are in good shape as well as haivng him handle the long side shaft(shortened) First question is what order does the spindle, brake caliper bracket, and stock brake backing plate go onto the axle? Is the spindle on the knuckle? Or would the brake backing plate go between them? Is there something else I should be looking at? I replaced EVERYTHING with new parts: seals, shafts(didn't have any), bearings, etc.... even the slingers that go on the outer shafts. Any advice on where I should focus my efforts would be GREATLY appreciated. I did search and I also looked at BV's Dana 60 tech article. Sadly, the exploded diagram doesn't show the brake backing plate

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07-30-2005, 08:43 PM	#2 (permalink)
mike Registered User Join Date: Feb 2000 Member # 144 Location: Northern Mexico... er.. AriDzona Posts: 6,867	Cant move the shafts in and out? or cant rotate them? edit: never mind reread it. Are the inners as hard to move?

07-30-2005, 08:58 PM	#3 (permalink)
Lil'John Zeus of the Sluice Join Date: Feb 2000 Member # 278 Location: Under a N. CA carport wrenching on my FJ55 Posts: 4,565	I can't turn them at all if I have the spindles fully tightened to the knuckle. If I don't have the spindles fully tightened, it is VERY easy to move.

07-30-2005, 09:01 PM	#4 (permalink)
mike Registered User Join Date: Feb 2000 Member # 144 Location: Northern Mexico... er.. AriDzona Posts: 6,867	sounds like the outers ears are jamming on the spindle.