The Dana 60 is an axle assembly used by the big three auto makers from the 1970s to the 1990s in trucks. There are rear- and front-end, four wheel drive models. These cast axle assemblies are ideal for towing and off-roading due to their heavy-duty construction and toughness. You need the correct tools and parts, when setting up a Dana 60, to ensure optimal performance.
Clean Environment
It is essential to work on the vehicle in a clean environment to minimize the chance of debris getting into the gear housing. Perform the setup in an inside area, such as a garage or barn, if possible. If you're doing this outside, try to minimize the time that the housing cover is removed or cover it with plastic or a towel when you're not working on it.
Tools
You should have all the tools necessary to perform the gear setup available and accessible before starting the job. The tools you will need include standard socket and wrench sets, along with a dial indicator, measurement calipers, a bearing puller and torque wrench. You will need a press for the bearings, or you can have a local automotive shop press them for you for a small fee. Many parts stores will loan you tools for free so you don't have to invest more money than necessary in this process.
Parts
Setting up a Dana 60 rear end requires only a few parts, but it is critical that you have them on hand before starting the job. An install kit, available at local auto parts stores or online off-road sites, contains carrier shims, pinion shims, an oil sling and housing seal as well as gear dye that allows you to see how the gears are meshing. You should also have a thread locker to use on any internal bolts to prevent them from loosening under the motion of the gears.
Set Up
Setting up a Dana 60 takes patience as it may take several tries before you get the ring and pinion gears in properly to check for adjustment. If you disassembled the gears, note how many shims were used and use this as a starting point for your new setup. Add or remove shims one at a time and check the lashing between adjustments. Take your time adding and removing shims as the lashing has to be exactly right or the gear assembly will fail prematurely. Replace the pinion nut with a new one for final assembly as it can get damaged from the constant loosening and tightening during adjustments.
