Dana 60 Big 35 Spline Inner and Stub Axle upgrade from 4WDFACTORY.com
By BillaVista


 

Part 4 - Assembling new shafts and u-joints

No sense in installing those shiny new shafts with a bunch of old, rotted out seals and rusty bearings.

I purchased 2 spindle seal and bearing kits locally. They can be a bit of a bear to find, so if you're reading this Greg, it might be an idea to offer them as an add-on to the 35 spline kits.

I for one highly recommend using all new bearings and seals, especially while you have everything apart.

Here is an exploded diagram and part numbers for the seals and bearings

Diagram # Description Dana Spicer # Timken # GM # Ford #
56 Stone Guard 37308      
57 Inner Spindle seal  620062 710044 14012967 D8TZ1175C
58 Thrust washer        
59 Outer spindle seal  37311 710045 462811 D8TZ1175A
60 Spindle needle bearing  620063 B2414 1400967 D8TZ3123A
57, 58, 59, and 60 Spindle seal and bearing kit  700014 SBK3 14009626  

I use a small aluminum bearing/seal driver and a BFH to install the new "Torrington" needle bearing into the back side of the spindle.

Don't ask how I got the old ones out - it was an embarrassing, frustrating, and altogether not very technical mixture of heat, blunt objects, brute force and cussing. - in other words - nothing at all you could learn from!

The metal "dust shields" or "stone guards" or "slingers" are not included in the spindle kit (but everything else is), so they have to be removed from the old stub shafts and reused.

Alternatively you can order new ones - the Spicer part number is 37308 (for GM and Dodge), and I expect the Ford are exactly the same.

Grease the new stub shaft liberally
Tap the stone guard into place
Then place the inner spindle seal on with the lip facing out.
Next place the thrust washer on with the "chamfer" facing in (or the perfectly flat side facing out).
And finally, place the outer spindle seal on with the lip facing in.
Then grease everything liberally, ready to go into the back of the spindle.

These two pictures clearly show the order and orientation of the seals and washer.

Once you have the stub shafts all geared up, it's time to assemble the inner and stub shafts with the new u-joints.

 

 You will need a reasonably clean workspace, a grease gun, a large hammer, a large socket, and a small standard screwdriver.

First, remove all the bearing caps from the trunnions of the cross. With the new Spicer Life Series u-joints, the seals are so good you may have to use pliers to remove the caps - they are extremely hard to remove by hand.

Place a moderate amount of grease in each cap. Do not go overboard, as excess grease in the cap during assembly will cause excessive hydraulic force and make assembling the u-joint very difficult. I just put a good dab in the cap then wipe it around the needle bearings with a finger. the joint will be fully greased after assembly.

Place the cross in the bores of the yoke of the stub shaft, with the grease nipple hole facing in (towards the inner shaft)
Raise the trunnion up in the bore and place a bearing cap on it
Drive the cap into the bore with a hammer....
...until the groove in the cap for the snap ring is visible inside the yoke.
Tap the snap ring into place
Raise the opposite trunnion up in it's yoke bore
Place its bearing cap on
Then place the yoke, with the bearing cap that already has its snap ring installed, on a large socket whose ID is larger than the OD of the bearing cap...

...and tap the other bearing cap into its bore until the snap ring can be inserted

With both snap rings installed, rotate the cross and check for binding.

If the joint is tight, you can attempt to relieve pressure by striking the ear of the yoke sharply. If this fails to allow the joint to rotate firmly (not sloppily) but without binding or over-tightness, you will have to disassemble and inspect. It is likely that one of the caps may have a toppled needle bearing.

Place the stub shaft with u-joint installed into the inner shaft yoke so that one of the trunnions protrudes through the top of the bore.

Then essentially repeat the entire procedure as above to install the other 2 bearing caps

Here the last bearing cap is about to be installed

Be careful when installing the snap rings that they are straight and properly seated in the groove, otherwise you will bend one, like I did here, as you drive on the opposite bearing cap. Doh!

When all the caps are on and clips installed, install the grease nipple, the grease the joint until fresh grease purges from all 4 seals. Then do a final check for any binding in the u-joint.

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