Jana 76 TM, Or how to install 70s in your 60 - Pirate4x4.Com : 4x4 and Off-Road Forum
 
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Old 01-09-2011, 10:35 PM   #1 (permalink)
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Jana 76 TM, Or how to install 70s in your 60

The Jana 76 & 54 thread got a little long with all the options for other diffs as well, so this thread will discuss Jana 76's only.

To start with there are several versions of D70's (70, 70U, 70HD, 70B, etc.) but they all use the same ring & ring & pinion, The differences are just bigger bearings and bigger castings and different housing dimensions, depending on gear ratio. All the commercially (desirable) Dana 70 high and low gear sets can be fitted into Dana 60's with our Jana Hybrid kits. Here is set of Dana 70 5.86's in a front 60 with an ARB D70 air locker.Name:  sm arb J76.jpg
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Update:
If you found this thread you'll also be interested in our full product line of Differential Hybrids;

HOW TO INSTALL:
Load Bolts into Stock housings:https://www.pirate4x4.com/forum/showthread.php?t=1059807
D80 into D70s, Jana 87;https://pirate4x4.com/forum/showthread.php?t=958266
D50 into D44s, Jana 54:https://pirate4x4.com/forum/showthread.php?t=948996
New 8.9" JKs into 44s Jana K4:https://pirate4x4.com/forum/showthread.php?t=957491
Holding it all together, Jana Cover Girdles;https://pirate4x4.com/forum/showthread.php?t=958047
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Old 01-09-2011, 11:09 PM   #2 (permalink)
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How its Done

1st, we have to get the larger gear in the housing. Since the D70 ring gear is 3/4" larger in diameter the than the D60 ring gear there needs to be 3/8" clearance around the D60 ring gear in the housing to clear the D70 gear, most 60 housings are cast with approximately 1/4" clearance, so only an 1/8" of grinding in a few spots is necessary.

2nd, we have to get the pinion in, and it needs to go roughly 3/8" farther out from the center line line of the ring gear, To do this an adapter pinion head bearing is used setting the pinion depth deeper into the bore. (notice step in upper left bearing race) this then moves the tail bearing, seal & yoke farther out, but luckily there is still room to get the parts in with the proper spacers, shims and adapter rings.

3rd, The 70 Pinion gear is also a bit larger thus the carrier needs to be moved away from the new pinion gear about a 1/16" for clearance. Again a narrowed adapter bearing is used to accomplish this without any loss in bearing load carrying capacity.

The Kit pictured here comes with all you need to start with a bare housing and install a D70 gear set & carrier. We start with a master overhaul kit and then add the required adapter bearings, spacers, shims etc to get the job done, and I'm told the stickers alone will add 6-7 hp!
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Last edited by unRL; 01-18-2011 at 09:00 PM. Reason: clarity, I used wrong picure originally.
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Old 01-09-2011, 11:50 PM   #3 (permalink)
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Cost Benefit Analysis

1st the Benefits,

Your Ring & Pinion is 33% stronger! with no loss of ground clearance.
Dana rates the 60 @ 6000 Ft-lbs maximum momentary output torque. 35 spl HD.
Dana rates the 70 @ 8000 Ft-lbs maximum momentary output torque. Non HD.
That's a 2000 ft-lb increase in capacity.
Also if you have alloy axles, then your current week link is the most difficult and expensive part to repair ie, the ring & pinion. Lets not have that.

2nd the Cost,

The net cost is only $150 bucks, and a couple more hours labor.
If you compare the cost of a Dana 70 gear set and carrier/locker to the cost of a Dana 60 gear set and carrier/locker, you will find they are within few bucks of each other. Now if your gonna do this right then you need a new installation and bearing kit as well, this is gonna set ya back about $150.

The cost of a Jana 76 kit is only $300* (most kits, subject to change).
Thus net cost around $150.
Folks, this is a No brainer

*May also purchase, Axle tube seals, HD yokes, & Jana cover girdle (more on this later)

Pictured is a Hi Pinion 60 with a set of Dana 70 5.13s on a Power Lock.
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Old 01-10-2011, 12:11 AM   #4 (permalink)
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Investment

The prior Cost benefit analysis was based on starting with a bare housing, Now many folk will already have a lot invested into their Dana 60 already when bam! crunch! the ring & pinion breaks! Your 1st thought will now be "I need a 76" your next thought may be "I have a bunch of money already in my Locker, spool, ARB etc.......hummmm.......is there any way I can use my current unit with the 70 gear set." The answer is yes In some cases, but it takes some machine work. The ring gear bolt pattern is different and the ring gear register is also different. We can plug your current ring gear holes and redrill the new bolt pattern, along with supplying a press on concentric adapter ring. $200-300. If you have an ARB we change out part of the case with 70 ARB parts & do a little machine work.
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Carl Jantz A.S.,B.S.,M.E. & S.O.H.Ks. SUPER JP ,42 Flat Fender, 25" stretch, JANA 76's, 300M, ARBS, 5.89's, 47s, SM420, Ranger overdrive, Dual disk McCleod, PTO, 4:1, Home made bead locks, and Patented the Yukon Superjoint.
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Old 01-10-2011, 12:45 AM   #5 (permalink)
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Rounding up parts

We of course can sell you everything necessary for this hybrid conversion. But there are also plenty of wrecking yard finds for the cost conscious.
The question I get the most is " will this or that Dana 70 carrier I find work with the kit" The answer is that they all will work, some easier than others. To keep this simple lets make the following assumption, You will be using gears 4.56* or up numerically. Now because of the larger pinion diameter the carrier needs to be a bit farther away from the pinion to get the backlash correct. There are 2 basic series of carriers for the 70s. The ones for 4.10 & down, and the ones for 4.56 & UP. The offset of the carriers is 1/8" but we only need to move about 1/16". The Narrowed carrier bearing supplied allows us to do this as follows:

If you have a 4.56 & Down carrier, it will be to close, move it away (Inst Narrow bearing on Ring gear side).
If you have a 4.10 & up carrier, it will be to far away, move it closer (Inst Narrow bearing on Pinion gear side)

Now there is a little more to it for all the possible combinations, before asking any questions please follow this link to Post 23 and read through the installation instructions to at least Post 38, then come back here and Please! ask any more questions you might have.
https://pirate4x4.com/forum/showpost....3&postcount=23

*If you are Installing 4.10 & up gears you will be best off with a 4.10 & carrier and it will be to close so move it away.
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Carl Jantz A.S.,B.S.,M.E. & S.O.H.Ks. SUPER JP ,42 Flat Fender, 25" stretch, JANA 76's, 300M, ARBS, 5.89's, 47s, SM420, Ranger overdrive, Dual disk McCleod, PTO, 4:1, Home made bead locks, and Patented the Yukon Superjoint.
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Old 01-10-2011, 09:19 AM   #6 (permalink)
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Here are some before and after pictures. This is a Chevy Dana 60 front housing with 4.56 gears and a Detroit locker. Top picture is 60 parts, bottom picture is Jana76 parts installed.
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Old 01-10-2011, 09:23 AM   #7 (permalink)
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This is a comparison between the Dana 60 and 70 Detroits, ring gear diameter (9.75" vs 10.25") and pinion head diameter on Dana Spicer 4.56 gears.
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Old 01-10-2011, 09:28 AM   #8 (permalink)
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Dana 60 pinions are undercut where the inner pinion bearing sits (right). Dana 70s have a small radius and special shims. Dana 60 shims need have the inside diameter opened up with a die grinder to sit flat on the 70 pinion.
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Old 01-10-2011, 09:32 AM   #9 (permalink)
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On my Chevy front housing the rough casting by the inner pinion race had to be smoothed out to clear the race. This picture shows where I tried to install the race but it was hitting.
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Old 01-10-2011, 09:35 AM   #10 (permalink)
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I reused my 60 pinion yoke and installed the spacer between the yoke and bearing, they are different for mockup and final assembly. The Jana 76 kit includes all the spacers needed.
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Old 01-10-2011, 09:38 AM   #11 (permalink)
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A little grinding was needed to fit the large diameter ring gear. The housing is a 1986 Chevrolet K30 front and it didnt need much more to clear. A little on the top, bottom and dam.
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Old 01-10-2011, 09:42 AM   #12 (permalink)
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I took the guts out of the Detroit because it was heavy and I had it in and out of the housing about 20 times.
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Old 01-10-2011, 09:48 AM   #13 (permalink)
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I did the swap because all the teeth were cracked on my 60 ring gear and I caught it before they broke completely. The 60 diff cover did not fit back on because of the larger ring gear. A stock 70 rear cover does not fit either. I had an aluminum one that fit. Thanks Carl!
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Old 01-10-2011, 09:51 AM   #14 (permalink)
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D50 upgrade ???

Quote:
Originally Posted by Consaka View Post
Now is a solid axle d50 housing the same size as that housing? Without measuring every little thing it looks very similar. It would be interesting if that housing could take a d50 d60 and d70 [email protected] setup.
You cant' fit the 60's into the 50 because even though the housing may be big enough to fit the ring gear, the hypoid distance is 7/8" different and no reasonable amount of machining will get you there.
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Old 01-10-2011, 09:53 AM   #15 (permalink)
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Great product and Carl is a stand up guy that can answer all your questions. We're running the Jana 76 in a front LP 60, it fixxed the ring and pinion issue. Now the 35 spline stub is the new weak link. Time for the 40 spline stuff.
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Old 01-10-2011, 10:15 AM   #16 (permalink)
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Nice Detail

Quote:
Originally Posted by Corey Young View Post
I did the swap because all the teeth were cracked on my 60 ring gear and I caught it before they broke completely. The 60 diff cover did not fit back on because of the larger ring gear. A stock 70 rear cover does not fit either. I had an aluminum one that fit. Thanks Carl!
Corey, very nice details on the intricacy of the install, Thank you very Much!
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Carl Jantz A.S.,B.S.,M.E. & S.O.H.Ks. SUPER JP ,42 Flat Fender, 25" stretch, JANA 76's, 300M, ARBS, 5.89's, 47s, SM420, Ranger overdrive, Dual disk McCleod, PTO, 4:1, Home made bead locks, and Patented the Yukon Superjoint.
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Old 01-10-2011, 03:49 PM   #17 (permalink)
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Quote:
Originally Posted by unRL View Post
You cant' fit the 60's into the 50 because even though the housing may be big enough to fit the ring gear, the hypoid distance is 7/8" different and no reasonable amount of machining will get you there.
Thanks

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Old 01-10-2011, 09:21 PM   #18 (permalink)
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Carl sends a very thorough kit. Lots of shims and even a new seal is included.
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Old 01-10-2011, 09:28 PM   #19 (permalink)
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We used a 4" angle grinder and a die grinder with a barrel-type sanding disc.
Material was removed slowly and the setup was in and out of the housing maybe 15 to 20 times checking clearance. This was so that only the minimum amount of casting had to be removed.
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Old 01-10-2011, 09:43 PM   #20 (permalink)
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The D70 R&P does fit with clearance in just the right areas. D70 beef with the ground clearance of the D60!
The diff cover did not clear the D70 ring so we cut a slot in the 1/4" material and added 3/8" plate over the opening.
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Old 01-10-2011, 09:53 PM   #21 (permalink)
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After 3 ring and pinions, something had to be done. Big Thanks to Carl for making this upgrade a reality.
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Old 01-10-2011, 10:53 PM   #22 (permalink)
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Shave and Thanks

Nice shave on the bottom of the diff, and I think the pics you took are better than any or mine or Crawl Mag. (sorry JH). Sweet cover mod, that probably didn't take very long at all. All it needs now is that J76 sticker on the front, and I'm told the sticker alone is worth 5 hp. LOL
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Old 01-15-2011, 05:39 AM   #23 (permalink)
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Quote:
Originally Posted by unRL View Post
1st, we have to get the larger gear in the housing. Since the D70 ring gear is 3/4" larger in diameter the than the D60 ring gear there needs to be 3/8" clearance around the D60 ring gear in the housing to clear the D70 gear, most 60 housings are cast with approximately 1/4" clearance, so only an 1/8" of grinding in a few spots is necessary.

2nd, we have to get the pinion in, and it needs to go roughly 3/8" farther out from the center line line of the ring gear, To do this an adapter pinion head bearing is used setting the pinion depth deeper into the bore. (notice step in lower left bearing race) this then moves the tail bearing, seal & yoke farther out, but luckily there is still room to get the parts in with the proper spacers, shims and adapter rings.

3rd, The 70 Pinion gear is also a bit larger thus the carrier needs to be moved away from the new pinion gear about a 1/16" for clearance. Again a narrowed adapter bearing is used to accomplish this without any loss in bearing load carrying capacity.

The Kit pictured here comes with all the adapter bearings, shims, seals, spacers, nuts, bolts etc for you to start with a bare housing and install a D70 gear set & carrier.
Do we need this kit to start from a bare housing? Does it come with carrier bearings?

Last edited by lightnin; 01-15-2011 at 05:47 AM.
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Old 01-17-2011, 01:33 AM   #24 (permalink)
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kit contents

Quote:
Originally Posted by lightnin View Post
Do we need this kit to start from a bare housing? Does it come with carrier bearings?
Yes kit comes with carrier bearings one stock and one adapter to get it all in. All you need is a bare housing, a ring & pinion and a carrier and my kit does the rest.
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Old 01-17-2011, 04:47 AM   #25 (permalink)
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Awesome. Thanks
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