D60 rebuild/regear

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D60 rebuild/regear

Postby liftarc » Tue May 31, 2016 9:15 am

This is for my Ramcharger but since the axles are the same I figured itd be ok to ask here...

I have a D60 rear from a 76 W200 lsd 4.10 and a D60 front from a 92 W250 3.54.

I went to swap the yoke on the rear 60 and the pinion bearings are gone, half inch of slop at least. I didnt pull the rear cover yet, I was so pissed I had to walk away.

So Im looking at a full rebuild of the rear, and a regear on the front (3.54 to 4.10). Is this doable as a shadetree gearhead? I dont have the deal to spread the housing, a shop press or bearing pullers. Are there practical work arounds? Also, how hard is it to redo the shims for gear mesh?
92 D350 club cab flatbed dually-201k G360, NP205,D60 swap soon
92 Ramcharger 5.9 Magnum, 46rh, NP241-238k
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Re: D60 rebuild/regear

Postby CumminsPower59 » Tue May 31, 2016 9:54 am

I just rebuilt the D70 for my 91, I have a press, but didn't use it. I don't have the case spreader, as you can work around that. As for bearing pullers, they sure are nice to have. One trick is to pre-heat the bearings with a propane torch, and they'll expand enough that they slide right on.

As for the shims, I had enough stuff laying around from other projects to get a good pattern and pre-load. It is easier to get a whole kit though. I put a used 3.07 gear set in the housing, and had to move the carrier shims a bit and add a fair amount of shims to the pinion to get the correct pre-load. I bet I pulled the carrier bearings six times...I probably should've bought set up bearings, but my inner cheapness won on that deal...
Ike

91 W350 SRW, 3.07's, NV4500, 370's, THD LPPP, Super HX40, 2nd gen IC swap, BHAF, Isspro's, 2" lift, 285's on 3rd gen 17"'s.
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Re: D60 rebuild/regear

Postby liftarc » Thu Jun 02, 2016 9:28 pm

Thanks for the input, I guess Ill know more of what Im up against when I tear it down this weekend and see the extent of the damage.
92 D350 club cab flatbed dually-201k G360, NP205,D60 swap soon
92 Ramcharger 5.9 Magnum, 46rh, NP241-238k
liftarc
fuel screw!!!!
 
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Re: D60 rebuild/regear

Postby DodgeFreak » Wed Jul 27, 2016 8:32 pm

Ike, if I was to install a lsd out of another rear, I should be able to swap the ring gear and then set up backlash and check wear pattern correct? Pinion preload I shouldn't have to worry about if I'm running the same pinion and I'm not removing it. correct?
92 D350 Cab and Chassis. Auto stock, wiring gremlins. 330k miles
92 W250 Ext cab rotted completely out. Auto, pump maxed, 215 ppump nozzles, Denny T2 pin.
85 D350 single wheel, converted to cummins, getrag, turned up 2 turns and afc screw flush.
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Re: D60 rebuild/regear

Postby PToombs » Fri Jul 29, 2016 5:41 pm

That's what I did Zach. I kinda wish I had pulled the pinion and replaced the bearings, but too late now! I bought extra bearings for set up and honed the inside of the race so they slid on and off easy, it worked good. It was a SOB pulling the carrier and changing shims so many times, but I got it.
pete

Just enough power to break everything behind the crankshaft.
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Re: D60 rebuild/regear

Postby DodgeFreak » Fri Jul 29, 2016 6:42 pm

Did you just use a 3 finger hone? Or something fancy?
92 D350 Cab and Chassis. Auto stock, wiring gremlins. 330k miles
92 W250 Ext cab rotted completely out. Auto, pump maxed, 215 ppump nozzles, Denny T2 pin.
85 D350 single wheel, converted to cummins, getrag, turned up 2 turns and afc screw flush.
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Re: D60 rebuild/regear

Postby PToombs » Sat Jul 30, 2016 5:37 pm

Ummmmmm, not sure if I should tell........ I took it to my buddies machine shop and he did them on the connecting rod hone machine. :lol:
pete

Just enough power to break everything behind the crankshaft.
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Re: D60 rebuild/regear

Postby liftarc » Mon Apr 17, 2017 7:45 pm

I finally tore down my '92 d60 front and noticed the bores on the steering arms for the tie rod ends are both badly stretched out. I looked at a 60 on a buddy's rig and same deal. Is there a way to fix this short of new/aftermarket knuckles or high steer conversion? Material is cast iron not forged steel right?
92 D350 club cab flatbed dually-201k G360, NP205,D60 swap soon
92 Ramcharger 5.9 Magnum, 46rh, NP241-238k
liftarc
fuel screw!!!!
 
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Re: D60 rebuild/regear

Postby CumminsPower59 » Tue Apr 18, 2017 9:09 am

Stretched as in ovaled out so much that the taper of the tie rod ends don't fit nice and tight?

There are a couple companies making aftermarket knuckles, and they are pretty proud of them too.
Ike

91 W350 SRW, 3.07's, NV4500, 370's, THD LPPP, Super HX40, 2nd gen IC swap, BHAF, Isspro's, 2" lift, 285's on 3rd gen 17"'s.
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Re: D60 rebuild/regear

Postby liftarc » Tue Apr 18, 2017 9:28 am

Yeah, the stud wobbles in the hole on one. Other side isnt as bad but still clearly visible.

Aftermarket knuckles are stupidly expensive but thats what Im leaning towards as a (hopefully) permanent fix.

Edit: not that I want to spend that money, thats why Im asking around trying to find a cheaper fix.
92 D350 club cab flatbed dually-201k G360, NP205,D60 swap soon
92 Ramcharger 5.9 Magnum, 46rh, NP241-238k
liftarc
fuel screw!!!!
 
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Re: D60 rebuild/regear

Postby CumminsPower59 » Wed Apr 19, 2017 12:12 pm

I wonder if there are any options for oversized tapered tie rod ends, say from another application. That way you could have the tapered sections on the knuckles reamed out and you wouldn't have to buy $600 knuckles...?
Ike

91 W350 SRW, 3.07's, NV4500, 370's, THD LPPP, Super HX40, 2nd gen IC swap, BHAF, Isspro's, 2" lift, 285's on 3rd gen 17"'s.
04 VW Jetta Wagon TDI 5speed
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Re: D60 rebuild/regear

Postby liftarc » Wed Apr 19, 2017 5:31 pm

Seems like that would weaken the fatigued metal even more. Theres a set of used Dodge knuckles on ebay, dude wants $275 plus $97 to ship them, well over half the price of new aftermarket. Not sure which way Im going yet.

After looking at aftermarket options Im wondering, what is the purpose/benefit of deleting the kingpin preload springs? Is there any reason to run bronze bushings? Premium grade snake oil?

Edit: theres a long list of threads from a bunch of wheeling forums of guys welding plate and gussets to these knuckles. Some use ni rod but even the ones done with hobby level mig squirts seem to hold up well with pre and post heat. Consensus seems to be that the material is cast steel not cast iron. Im going to do a spark test when I go home this weekend.
92 D350 club cab flatbed dually-201k G360, NP205,D60 swap soon
92 Ramcharger 5.9 Magnum, 46rh, NP241-238k
liftarc
fuel screw!!!!
 
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Joined: Thu Mar 03, 2016 1:28 pm
Location: State of Jefferson
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Re: D60 rebuild/regear

Postby PToombs » Thu Apr 20, 2017 4:37 pm

I think if it was mine I would weld in the holes and then shape them with a die grinder before spending that much money for new ones. JMO. ;)
pete

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Re: D60 rebuild/regear

Postby matthewh » Fri Apr 21, 2017 12:40 am

Another idea would be to drill out the hole and weld in a piece of thick wall tubing. Then take it to a machine shop, or buy a tapered reamer and re-taper the hole.
'93 W350 5spd Getrag, 4.10 gears, 83k miles and counting, Mods: LPPP AKA Ma Dually
'54 Dodge M37 6.2/700R4/205, 5.89 gears, WC rear axle
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