Wildman's TJ is getting a face lift
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Wildman
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Looks like I have another little project to do. I needed to set it up under the rig anyhow so I'll mark the SPOT where my drain plug is at while I'm doing that. Having a non-stock rig can be so much fun.
FedEx updated when the V-Band clamps are gunna be here. Yesterday I was a little excited as they'd sad they would arrive today but they only made it as far as Troutdale, OR. Now they are suppose to arrive Sunday but I ain't gunna hold my breath.
Wildman
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I started off thinking I'd done something stupid when I couldn't find the carrier bearing that I'd pilled off the ARB. So I'd given up looking for it and was just going to use the new bearings instead. Then I opened up the box with the gear install kit and there was the old bearing.
So I spent the next hour or two making setup bearings for the CRD60. Setup bearings can be bought or made. If you are installing new bearings into your axle and the bearings are good then you can take flap disc and turn them into setup bearings.
80 grit and & dremmel works wonders. You want to take off just enough that the bearing will slide onto and off the carrier & pinion gear with a small tug.
It takes a few OK more than a few test fits until you get just enough off.
Slides on with a little push.
And then slides back off with a small tug.
So now I have setup bearings for a Dana 30 & Dana 44 and now a Dana 60.
Then I cleaned up the shims so I can measure them so I have a starting point when installing the new gears.
I'll have to say this is a rather large shim stack and am not sure why those old gears took so much to setup. We'll have to see what these new gears take.
Before I can start to setup the new gears I've got to get the load bolt installed but as with everything on this rig it's never easy. If it was a standard Dana 60 Carl already has the measurements for how deep the load bolt needs to be installed. But it's not a standard Dana 60 so I have to follow his video and find out the depth that it need to be at.
I was cleaning the inside of the housing and I think I found a lot of the pieces of the broken pinion teeth.
So I flushed the housing 3 times with brake clean until the rag came out clean. I'll get started on the load bolt layout tomorrow.
So I spent the next hour or two making setup bearings for the CRD60. Setup bearings can be bought or made. If you are installing new bearings into your axle and the bearings are good then you can take flap disc and turn them into setup bearings.
80 grit and & dremmel works wonders. You want to take off just enough that the bearing will slide onto and off the carrier & pinion gear with a small tug.
It takes a few OK more than a few test fits until you get just enough off.
Slides on with a little push.
And then slides back off with a small tug.
So now I have setup bearings for a Dana 30 & Dana 44 and now a Dana 60.
Then I cleaned up the shims so I can measure them so I have a starting point when installing the new gears.
I'll have to say this is a rather large shim stack and am not sure why those old gears took so much to setup. We'll have to see what these new gears take.
Before I can start to setup the new gears I've got to get the load bolt installed but as with everything on this rig it's never easy. If it was a standard Dana 60 Carl already has the measurements for how deep the load bolt needs to be installed. But it's not a standard Dana 60 so I have to follow his video and find out the depth that it need to be at.
I was cleaning the inside of the housing and I think I found a lot of the pieces of the broken pinion teeth.
So I flushed the housing 3 times with brake clean until the rag came out clean. I'll get started on the load bolt layout tomorrow.
What’s a setup bearing???
Oh that’s right - I have a 14 bolt…..
Happy New Year my friend!
Oh that’s right - I have a 14 bolt…..
Happy New Year my friend!
Wildman
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We all can't be running the BIG DOG rear end... Now if I break another R&P I just might be looking at going to a 14B but I'd rather keep a HP axle in the back of mine if possible.What’s a setup bearing???
Oh that’s right - I have a 14 bolt…..
Happy New Year my friend!
Happy New Year to you also Jeff.
Wildman
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I did some measurements just because I was curious about what the difference between a Dana 60 and Super60 was.
Hard to tell a difference until you measure them.
Dana 60 ring gear
Super60 ring gear
Dana 60 pinion gear
Super60 pinion gear
Hard to tell a difference until you measure them.
Dana 60 ring gear
Super60 ring gear
Dana 60 pinion gear
Super60 pinion gear
Wildman
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I followed his video and installed the carrier with the guide plate installed and measured the distance to it. The measurement came the same as what he has specified for a Dana 60. Which honestly makes sense because the housing has to be the same to fit a Dana 60 pinion gear.
My install of the load bolt is going to be a lot more interesting since the rib on the housing is RIGHT where I need to drill my hole for the load bolt. So from when he stopped by plus the measuring I've done today I have a good idea where it needs to go.
I've got my marks on the axle housing and tomorrow I'm going to cut the rib so I can start my hole.
The actual spot is the line on the left which is where the load bolt hole will go.
Then I also had to clearance the ARB housing for the load bolt to clear it and be able to ride off the back of the ring gear. But a little time with the grinder made it clear and I'm ready to start the install process. I need to setup the gears with the proper pattern before I drill the hole so I'll be playing with it tomorrow. I have my fingers crossed I get a good contact pattern FAST as that thing is heavy I I don't want to be installing and pulling it a ton of times.
I also had one of the locking tabs for the case bolts fall off and I was missing one so that might be what happened to the pinion teeth. The lock tab could have come loose but I'd have thought it would have damaged the ring gear also if that was what had happened. So I ordered new ones plus new o-rings and setup shims. One of the bolts that was missing the lock tab was finger tight so it's a good thing I pulled it apart.
My install of the load bolt is going to be a lot more interesting since the rib on the housing is RIGHT where I need to drill my hole for the load bolt. So from when he stopped by plus the measuring I've done today I have a good idea where it needs to go.
I've got my marks on the axle housing and tomorrow I'm going to cut the rib so I can start my hole.
The actual spot is the line on the left which is where the load bolt hole will go.
Then I also had to clearance the ARB housing for the load bolt to clear it and be able to ride off the back of the ring gear. But a little time with the grinder made it clear and I'm ready to start the install process. I need to setup the gears with the proper pattern before I drill the hole so I'll be playing with it tomorrow. I have my fingers crossed I get a good contact pattern FAST as that thing is heavy I I don't want to be installing and pulling it a ton of times.
I also had one of the locking tabs for the case bolts fall off and I was missing one so that might be what happened to the pinion teeth. The lock tab could have come loose but I'd have thought it would have damaged the ring gear also if that was what had happened. So I ordered new ones plus new o-rings and setup shims. One of the bolts that was missing the lock tab was finger tight so it's a good thing I pulled it apart.
Wildman
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Went out late last night and messed around with the axle some more. This is a really interesting design compared to a stock axle housing. To get the nose bearing race out you need to remove the inner bearing race first. Then you have access to these 3 holes where you can get a punch. I only had a punch so long so had to breakout the slide hammer to take the last little bit.
Then installed the new race.
Since both my axles were built 15+ years ago I have what are now considered "Old Style" ARB lockers. The one in the CRD60 is the 3 piece design and has these bolts that hold the cap with the air cylinder in it. To help keep the bolts from coming loose ARB has these press fit lock tab that go down over the top of the head of the bolt. As I said before I'd lost one and assume it got chewed up but it could be in the gear oil. And then the one bolt was finder tight. If it had worked it's way out far enough it could have snagged on the side of the housing and then gotten broken off.
This is the tab that fell off plus one installed on a bolt.
The one bolt that was finger tight.
The bolt that the tab fell off of. I have a new set of tabs coming. For $9 it was cheap insurance to replace them all.
Then installed the new race.
Since both my axles were built 15+ years ago I have what are now considered "Old Style" ARB lockers. The one in the CRD60 is the 3 piece design and has these bolts that hold the cap with the air cylinder in it. To help keep the bolts from coming loose ARB has these press fit lock tab that go down over the top of the head of the bolt. As I said before I'd lost one and assume it got chewed up but it could be in the gear oil. And then the one bolt was finder tight. If it had worked it's way out far enough it could have snagged on the side of the housing and then gotten broken off.
This is the tab that fell off plus one installed on a bolt.
The one bolt that was finger tight.
The bolt that the tab fell off of. I have a new set of tabs coming. For $9 it was cheap insurance to replace them all.
Wildman
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Got the inner race installed also.
I'm seriously shocked at the amount of shims that were used. This was the shim pack behind the inner race.
Had one shim left over out of the install kit.
Got the load bolt marked out on the rib I'm going to have to cut. Just haven't got up the nerve to do it yet.
So while I built up the nerve I installed the new ARB fitting. This banjo will make running the air line a lot easier.
Comes out the front nicely
I'm waiting for FedEx to deliver the V-Band clamp so I can finish the Y pipe and take it Tuesday to get ceramic coated. They say it's getting delivered today.
I'm seriously shocked at the amount of shims that were used. This was the shim pack behind the inner race.
Had one shim left over out of the install kit.
Got the load bolt marked out on the rib I'm going to have to cut. Just haven't got up the nerve to do it yet.
So while I built up the nerve I installed the new ARB fitting. This banjo will make running the air line a lot easier.
Comes out the front nicely
I'm waiting for FedEx to deliver the V-Band clamp so I can finish the Y pipe and take it Tuesday to get ceramic coated. They say it's getting delivered today.
Wildman
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Had to come inside and make lunch and warm up a little. DAMN even with the heaters turned it's still cold out in my garage. It's 42* inside and 14* outside. So I'm going to read the install book that came with the gears while I warm up a little and then I'll think about going back out there.
Wildman
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It was -4 here last night and the night before. Suppose to warm back up to the low 30's this week.
i got lots of comozzi air fittings like these if y'all ever want or need a spare,
Wildman
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Wildman
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Well even the Super60 ring gear has clearance issues inside the CRD60 housing. Going to have to do a little bit of grinding.
The bottom clears no problem.
But up top where to oil slinger hole is that oils the outer bearing it's a bit tight.
It's hard to get a good picture so I hope you can see it.
The bottom clears no problem.
But up top where to oil slinger hole is that oils the outer bearing it's a bit tight.
It's hard to get a good picture so I hope you can see it.
Wildman
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This is the area that needs clearanced for the ring gear.
Wildman
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Did some grinding and tomorrow I'll drop the carrier back in and see if this was enough or if I need to take off a little more.
I may have missed it but couldn't you shave the ring gear instead of grinding the inside of the housing?
Wildman
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I guess yes I could of had the ring gear turned down but IMO grinding the inside of the housing was easier. If I'd gotten the Jantz 76 kit I'd be doing a lot more grinding to fit the Dana 70 ring gear.
Wildman
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Well FedEx actually came thru and delivered the V-Band clamps today. So I'll get the Y pipe welded up tomorrow so I'm ready to head across the pass Tuesday if it's open. We'll have to wait and see how much it's gunna snow tomorrow.