How hard would it be to change gears in a Dana 60? - Diesel Forum - TheDieselStop.com
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Power Strokes 1994-1997 Upgrades and Aftermarket Upgrading or adding OEM or aftermarket equipment to your 1994-1997 Ford F-Series with Power Stroke engine.

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Old 03-02-2005, 01:03 PM   #1 (permalink)
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How hard would it be to change gears in a Dana 60?

Guys how hard is it to change a Dana 60 Front from 3:55 gears to 4:10? [img]/ubbthreads/images/graemlins/shrug.gif[/img]
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Old 03-02-2005, 01:18 PM   #2 (permalink)
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Re: How hard would it be to change gears in a Dana 60?

I think it is about the same as the rear. Which I will be doing in a couple of weeks by adding 410's. If that is keeping you Paul, then let me know where it is and I will go and get it... [img]/ubbthreads/images/graemlins/grin.gif[/img]. You could always just take off the front drive shaft until you have the gears and money for someone to do it. If you have no experience then I think you would want someone to do it that has some. It is an artform from what I hear. I have an old school gearhead in my Pops so he will assist me while I do the work.

ART [img]/ubbthreads/images/graemlins/cool.gif[/img]
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Old 03-02-2005, 01:35 PM   #3 (permalink)
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Re: How hard would it be to change gears in a Dana 60?

wouldnt be that hard, just like setting up gears in anything else im sure. Just gotta make sure that you check the gaps! Change your rear to 3.55 the youll get real good fuel milage!! haha
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Old 03-02-2005, 02:55 PM   #4 (permalink)
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Re: How hard would it be to change gears in a Dana 60?

[ QUOTE ]
Change your rear to 3.55 the youll get real good fuel milage!! haha

[/ QUOTE ]Not with 35's [img]/ubbthreads/images/graemlins/eek.gif[/img] or 37's [img]/ubbthreads/images/graemlins/laugh.gif[/img] [img]/ubbthreads/images/graemlins/grin.gif[/img]
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Old 03-02-2005, 04:57 PM   #5 (permalink)
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Re: How hard would it be to change gears in a Dana 60?

Well you start by:
-Removing the tires
-Take the hubs apart
-Hang the brake caliper away
-Take the hub and disc off
-Seperate the spindle from the knuckle
-Remove steering rods away from front of D60 cover
-Open the D60 cover and drain the fluid
-Slide the axles out
-Take the carrier bearing caps off
-Take the carrier/ring gear out
-Remove the front drive shaft
-Remove the Pinion nut
-Knock the pinion shaft in

Now you have a stripped D60 housing. Don't loose any of the shims. There is set of shims on the pinion shaft and another set behind the inner pinion race.

Now comes the fun part. Do you install new axles, new seals, new bearings/races, locker/limited slip, etc. Change ball joints (your already there, whether you need to or not, they'll probably go when you put everything back together) Only your $$$$ flow will decide that. I would definitely install new seals. Dana/Spicer came out with new axle seals, awesome looking, the sealing surface is approximately 1.5" wide and double sealing area in the housing.

And when you assembling everything that could be exposed to the weather- ANTI-SIEZE

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Old 03-02-2005, 08:10 PM   #6 (permalink)
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Re: How hard would it be to change gears in a Dana 60?

I wish I would've known about those new seals, they sound alot better than the ford ones. I just got done buttoning everything up after replacing my axle oil seals with the ones from ford.

Bigstroker, I've never set up a ring and pinion but with it being the front axle I personally would probably go ahead and try it myself because if you notice any humming or grinding after you do it you can just use 2wd and still drive it till you can afford to let someone else do it.
But thats just my $.02 and I've always wanted to try this procedure anyways.
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Old 03-02-2005, 09:14 PM   #7 (permalink)
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Re: How hard would it be to change gears in a Dana 60?

whatchs doin with the 3.55's I need a front set.
will trade rear 4.10 for a set of front 3.55's.
I have front 4.10's but I think they will be shot due to the pionion bearings being bad.
and I have the rear 3.55's just need the front to convert .
Nick
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Old 03-03-2005, 11:13 AM   #8 (permalink)
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Re: How hard would it be to change gears in a Dana 60?

I would highly recommend reading this link first. http://www.ringpinion.com/downloads/yukoninstman.pdf

Bearing preloads are critical and require an inch pound torque wrench.

Backlash is also critical and requires a dial indicator and stand.

You can have all of your settings but one correct, make an adjustment to correct the one that's off, and move everything else as a result. Unless you are very patient and willing to press bearings on and off several times you're better off having it done at a shop. Every gearset is different as far as pinion depth and pattern, so it isn't a matter of unbolting the old and bolting the new back in.
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