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Old 03-30-2007, 10:09 PM
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Question How do you install new outer shafts on a 1 Ton GM Dana 60???

I have already tried searching the techinical archives but found nothing about replacing outer shafts.

What I have is a 1 Ton GM Dana 60 out of a military CUCV. One of the hubs croaked so I decided why not upgrade the outer shafts to 35 spline along with getting new Warn premium hubs as well.

Does anybody have a technical/mechanic's manual for this task OR know of a source
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Old 03-30-2007, 10:25 PM
bigjeepthing bigjeepthing is offline
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The bigger shafts use the same parts as the stock shafts except the hubs and the c clip on the end.
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Old 03-30-2007, 10:28 PM
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I would search over at pirate, those guys are into the big Dana 60 stuff more than the guys here.

Mike D.
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Old 03-30-2007, 11:05 PM
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No different than pulling the D44 apart. Calipers come off, hubs, wheel bearings, Hub/rotor, then spindle, pull axle out and press Axle joint out and put new one in along with new outer axle.
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Old 03-31-2007, 01:30 AM
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Quote:
Originally Posted by Crazy_Jeepman
No different than pulling the D44 apart. Calipers come off, hubs, wheel bearings, Hub/rotor, then spindle, pull axle out and press Axle joint out and put new one in along with new outer axle.

Never pulled an axle apart before I guess one would be alot like another though

Thanks for the info CRAZY_JEEPMAN

BTW ... do I, or should I, get a shop to press the old axle joints out and new ones back in


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Keep in mind. Getting old is easy. Being old is hard.
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Old 03-31-2007, 04:06 AM
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They aren't that hard to do at home with a combination of tools, you shouldn't need a shop to do it if you have some basic tools. Looking at what you plans are for your build I'd recommend that you just buy a u-joint tool right now though and save yourself some hassle on the current project and then take it with you on the trail and carry spare u-joints because those are going to be the weak link in your drivetrain (or fuse).
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Old 03-31-2007, 08:17 AM
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Yep, pretty easy. If you dont have the special socket for the wheel bearing nuts then you will need to buy or rent one. I would just buy one. It should have the 6 slot nuts. To take everything apart just do the following:

Remove brake caliper
remove lockout
remove wheel bearing nuts (two of them)
remove the hub/rotor assembly
remove 6 nuts holding the spindle on
remove spindle, these can be tough, use a plastic dead blow hammer or a block of wood between the spindle and a metal hammer. Do not directly hit the spindle with a metal hammer, it WILL mess it up!
once the spindle is off the shafts will come out.

If I were you, since you have it down that far, I would go ahead and just get new u-joints. Replace the spindle bearings and seals. Clean, inspect and re pack the wheel bearings, and install a new seal on there too.
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Old 03-31-2007, 01:36 PM
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Thumbs up

Thanks for the tricks, hints, and pointers guys!! It looks like I will be upgrading my tool selection as well.

Any other tips are greatly appreciated!!


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