After the Clayton trip I decided to go ahead and start the install of the RJ60 in the rear since the locker in the rear of the Dana 44 was popping. I was originally going to wait until I had found a front axle and do them at the same time, then I waffled back and forth on waiting to install the rear axle, but after Clayton I figured why put anymore money into the Dana 44 when I have the 60 sitting there in the garage. So I started the process of installing the 60.
The RJ60 I got had no brackets and it had a stock Dana diff cover. I went ahead and purchased a Currie Iron Diff Cover and the Bridge Kit and installed those, then I decided if I was going to install this new axle, I might as well try and fix my "hopping" issue during steep climbs so i decided to get rid of the short arms in the rear and install a custom setup.
I only have this one picture, which shows another great use for Soft Shackles in the garage, but I figured I would document what I have done up till this point for posterity and so I can remember it a year from now when I need to fix something. Possibly I will come back and add pictures later.
View attachment 375568
Axle:
Has Detroit Locker, 5.13:1 gears. 35 spline shafts, Semi-Float. Set 20 Housing End (Torino, late model Big Bearing). 1330 Big Cap Yoke.
-Removed the previous owners installed Taurus brakes and installed newly purchased Explorer brakes. Installed them flipped.
-Added the Currie Iron Diff Cover and Currie Bridge Kit. Welded up the existing breather hole (which interfered with the bridge install), utilizing the breather in the Currie Diff Cover.
-Utilized Hard and Rubber Brake Lines from Dana 44.
-Utilized the axle side spring perches and the shock mounts from the Dana 44.
-GR 10 deg LCA brackets (I cheated them up as much as I possibly could while still maintaining decent separation on axle and to also give the LCA as much travel up as possible before hitting frame. This took me about 3 trials of tacking on brackets before finding the right balance).
-GR 3" Upper Control Mounts were welded onto the Currie bridge.
-Current plan is to utilize my current TW drive shaft which is the correct length and to replace the existing Ujoint (which is shot) with a 1330/1330 Big Cap Spicer 5-1204X ujoint. This is still TBD.
Frame Side:
-Cut off existing brackets.
-Installed a set of GR 4 Link Brackets which were modified slightly.
-Upper Links are 1.75 aluminum links with LH and RH CE-9113 Johnny Joints (1"-14, 2 5/8 width, 0.563 bore)
-Lower Links are 2.0 aluminum links withe LH and RC CE-9114 Johnny Joints (11/4-12, 2 5/8 width, 0.563 bore)
-Cut slots in the Body wheel well area to allow for clearance of the upper links. Plan is to add "tunnels" to cover these slots in the future, but that has not been done yet.
-Brackets are installed right at the bend in the frame. Installed with fwd edge of channel right at this bend.
-Modified aft edge of skid plate on both sides due to frame bracket installed. Added new insert location just fwd and replaced the other nutserts since they were getting a little rough.
Additional Notes related to axle install:
-Had to add some bump stop (utilized aluminum BL pucks at the upper spring perch) with the bump stopping right before the LCA contacts the frame. With the body cut at the wheel wells, the LCA at the frame is the upper limit.
-The axle is pushed back approx 1" from the stock location in order to get everything to line up just right, this required me to trim the fenders.
-Shocks are set up with 50/50.
Other work accomplished during this time:
-Dropped the fuel tank and found out where my fuel leak was coming from. The two vents in the top of the tank were making contact with the body and it rubbed holes into the vent. Replaced the vents with Dorman 911-060 vents (thanks to Toximus build thread for that info!) and trimmed the body (and beat it a little) where the vents are located. Redid the vent line so that it extends past both sides of the tank and ends high in the wheel well.
-Steering Gear was leaking so I sent it back to West Texas OffRoad and they rebuilt it under warranty.
-Still need to regear the front to 5.13:1. I bought the R&P but have not installed yet.
Still have not driven it to see how it turned out. Due to time/travel/etc.. probably will be a few weeks before I get the opportunity.