Pirate4x4.Com - Extreme Four Wheel Drive

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

Part 5 - Installation

	Installing the shafts simply requires sliding them carefully back into the housing, again being careful not to nick or damage the inner axle seals.
	Once installed, they look like this
	Re assembling the rest of the components is simply the old "installation is the reverse of removal".
	When everything is back together (except the drive flanges), rotate the shaft in place and check to make sure the u-joint turns freely between the knuckle and end forging, that there is no binding or interference. Do this throughout the steering range of the knuckles. Ensure the grease fitting is accessable and not interfering.
	The last part of the assembly is to install the new warn 35 Spline Drive Flanges. First, take the 2 "wear washers" (the small flat washers, not to be confused with the stub shaft snap rings)....
	...and place them over the stub shaft.
	Then slide the drive gear in place over the stub axle. You may need to rotate the axles slightly to get the stub shaft splines, drive flange, and hub splines all lined up.
	Fully installed it looks like this.
	Next place the stub shaft snap ring over the end of the stub shaft and into the groove.
	Then place the drive flange cap retention plate in the hub...
	... and install the big outer snap ring.
	The last thing to do is tighten down the #8 Torx screws that are pre-impregnated with thread locker.
	And you're done!!!
	It's AWESOME how much less protrudes from the hub with the 35 spline drive flanges compared to lockout hubs. And of course, having the biggest 35 spline axles throughout brings a lot of peace of mind......

Testing

...And that peace of mind is great to have when you like to go out and Fully Get It like I do. Here are some shots and a short video clip of my first 2 runs since the install. From high torque, 110:1, crossed up, full-lock, bound-up rock crawling, to 6000 rpm full-throttle assaults on slick, muddy, rocky hill climbs - I did my best to break something...but everything has held up extremely well so far, and I really enjoy the extra clearance with the drive flanges tight to the hub body. Check out the pics and a short vide clip.

	Full lock, and throttling through a tight spot. Murder on joints and shafts...but not a problem for me now!
	A tough rocky climb - tried several ways - from crawling to throttling.
	Ummm...posing on the rocks! (guilty grin)
	Another brutal, low-low gear, caught-in-a-crack, rock crawling spot. I may have needed a spot of help to get out...but I didn't break, and I gave it hell trying! :-)
	Check out the smoking tires.....I love being able to attack things with confidence when required. that's why, as I mentioned way back in the beginning, I don't believe in designing in a weak link...let my courage be the weak link!
	Check out the video clip of one climb attempt. If you look closely you can see flames shoot from my exhaust. Make sure the sound is cranked up!