MG #78 - Dana 60 Teardown and Rebuild
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- Опубликовано: 23 янв 2025
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Rebuild and refresh on my Chevy Kingpin Dana 60. Making a great axle greater!
I stripped the axle down to tubes, inner c and housing and grinded, cut, welded, hammered and cursed.
I am halfway there with more to come shortly.
check out my Amazon Store. Tons of parts I use, products I believe in and tools I can't work without.
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Always enjoy the updates and now I enjoy watching you work. It’s nice to see a real garage build where you encounter all the problems. Not on a perfect shop on a lift with every tool imaginable.
+Nathan Brown thanks man. That is what I am trying to show. Brute force and ignorance are a powerful tool
Cool video -- did a great job capturing the essence of why we all get up early and go to bed late working on our vehicles.
videos like this one is why I subscribed. i have an 87 blazer and sometimes, watching other people just describe how to do things makes you feel like your doing something wrong due to the struggle. its nice to know I'm not the only one that has to spend hours trying to bust loose one nut or bolt! great video man.
yup, I always felt stupid when I spent days working on stripped bolts and the videos and shows are done in like 45 min. I know they skip over that stuff as it isn't compelling viewing, but I feel that people need to know that it isn't easy, we struggle, we curse, we fail. And then we get up the next day and deal with it.
Don't get discouraged man, your videos keep me wanting to work on my own 4x4. Your blazer is truly badass!
thanks man. I'll tell you what though, this last weekend was tough, dirty, frustrating, tiring and pain the neck work. Cutting all those horrible rivets off the frame to make way for the new brackets had me on the ropes.
I need a couple days off to recharge!
Merricks Garage from my experience with rivets on these old frames I can definitely understand. I've always hated messing with them and avoid it if I can
+Adrian Laverick yea. They absolutely suck
Great video - awesome content! Thanks for taking the time to share it with us.
Video was one of the best ones in a while. Showing the build. Great job.
Awesome video, I enjoy watching your progress and totally relate to all the detail work you are putting into this build. I always do the same on my truck.
Friends think I'm crazy, but I get looks and thumbs up everywhere I go from the street to the trails. Perfect length video, can't wait to see the next one. 👍
Thanks J. Great work as always.
I think you're right about the factory axle being bent.
Awesome stuff Merrick!
good video. The length was good for what you are covering here cause it's a bit involved, so it needs more time. Looking forward to the next part
Love the length and detail, could even go for more!
Might have to get longer steer stop bolts as you are going to loose some turning radius with the bigger outer knuckle. Also you might want to look at the length of the outer shaft. I had to shave mine a bit as it would over time auto engage the locking hub. WAIT. You did not go through your axle when you got it? Don't skimp! Replace all your races and bearing while you have it a part. Great video!
Perfect length and content. Looking at the rebuild on my dana 60, seems less daunting seeing you turn yours into that!
+BobcatM3 awesome. That is my goal!!
Just found a Dana 60 king pin passenger drop for 500 bucks and I came straight back to this video for the rebuild
Dang man! Appreciate it!! BTW that is a killer deal on the axle.
Looks good man. Another solid (front axle) video, ha!
i appreciate this kind of video, because most people in the real world, dont have there own mega shops with ESAB/ Miller welders, plasma cutters etc. or the bank account to buy Dynatrac stuff or the like...thanks
real life man real life. I would love to have a small work shop / area where I could start to spread out a little but that is not in the cards right now. Clean up is as important as the work, keeping the neighbors happy is crucial!
Great video!
Length was good keep them all like this
Loved the video man, it wasn't too long to where I had to skip parts, but just the right amount. As for the rest of the guys on here my k5 is doing the same thing. Waiting to be put back together and waiting for my bank account to be taken to ZERO again. But love the videos, keep it up!
+wyatt barnard lol $ is always the biggest challenge.
Great video man
I loved this video, very informative. Keep up the great work.
Great video you sold me on swapping my 208 for the 241 and a Dana 60 king pin and 14 bolt
+Cody Harrison great upgrades!
I like the whole video, beautiful details.
+The Cat Felix thanks!
Nice video can't wait for the next one keep up the awesome work
I love the lenght of the video man
I love this! This length was great! I'm excited to see to see how it turns out! My poor K5 is waiting on my wallet to get rolling down the road.
I got the same problem. I have a K5 with a Dana60 and 14 FF. I just put a crate 350 in it, but I think I need a new trans and xfer case - that's gonna hurt.
I enjoyed every minute of your vid I don't think it was.to long ..Learning ..
great to hear! Glad it helped out!
I had to chain my 60 to a tree and use a winch to pull the carrier out. Used a case spreader to put the Detroit in it. Case spreader is a must have on a 60, or your gears aren't going to last very long!
+Mark Gray I thought so too but my elocker wasn't that hard to install. Soft mallet and back and forth on the carrier and it was in
Nice. I had to use a case spreader. Great looking truck. My K5 is beat up doved front and rear and I love wheeling with the jeep guys! They don't know what to thing when I come rolling thru the woods!
Have you thought about moving the rear axle back when you 4 link the rear. I plan to with my bronco I am doing the 293/205 double transfer case swap and plan to do the 4 link at the same time so I will move the rear axle back the length the case extend so I keep the factory length drive shaft on the rear it already is a short shaft. Should be around 10".
+Dan Allen yea axle will move back. I should have done it with the leafs ( I moved the front forward) but forgot before I welded up the wrap bars
Great video liked the content. Keep up the good work. I am building an 89 ford bronco myself but like your videos.
+Dan Allen thanks man!
Awesome and informative vid as always.
Great video, Keep it up!
I think the length was about right. Looking forward to seeing the coil overs on the truck! I'd like to make a detailed 3d model of the blazer for a game after I see the coil overs on it. In prep for making a model, do you think you will have to do more trimming on the body or keep the body as is?
Looks like the shaft was bent. I wonder if the truck was rolled.
+Lance Roark lol. Yup
I think it’d be alright if you included more details and the video longer
Perfect!
I look forward to these 20-30 minute progress filled videos. (longer is ok too!) The content was great. Anything you may have missed or forgotten about now can always be mentioned/shown on the next step or reassembly stage. I watched your original build videos when I built my rock crawler K5 2 years ago, they were VERY helpful. I went to DIY4X and ORD for a lot of my build parts based on your recommendations, with zero regrets. (the A-Bomb...wow it's awesome, best mod I did) Annnnnnd now I HAVE to 4-link mine...thanks alot...I thought my build was finished....lmao. I do have a short vid of my K5 in action, check it out if you get a sec!
Btw: get yourself some of the bigger tin coffee cans or empty gallon paint cans. They're fantastic for keeping parts together during disassembly (locking hubs, bearings, nuts/bolts/hardware, diff internals, etc). They're much easier to move around for shop cleanup vs. having parts laying on a rag or a block of wood or on the floor. I put a mix of Simple Green/water in them when needed also. By the time you get to reassembly stage, everything is degreased and clean.
Are you planning to gusset the "C"s on the housing? Is the front driveshaft up to the task of the increased articulation you're going to have? Are you planning to clock your t-case up? Wheelbase/axle position changing?
+Sean Gill I don't think I will gusset the c's. I would have to get into some major crazy stuff if I was worried about them. The driveshaft u joint is my concern not the tubing. I moved to an agricultural shaft (male stub shaft, female main shaft) so the driveshaft is great. The axle is forward already and I will be pushing the rear back. One of the nice things about the links is the wheel travel is a lot more consistent and predictable compared to leafs so I can get more precise with axle placement
Why did you cut the brackets off? I'm looking into doing something similar but just don't know a ton yet.
I have yet to tear down an axle in any of my trucks, so this advice may not be all that helpful. I invested 50 bucks into a used acetylene torch setup (off kijiji; canadian version of craigslist) and that's helped make short work of things that used to be difficult. Rusty bolts that absolutely won't budge; torch em off in 5 seconds, then drill in a bit, stick a big punch in the and sledge. Just one example. Might be worth looking into if you can find the space for it. Bottle refills are cheap as well
When I rebuild my ten bolt it's getting the ol rattle can special
Time was right on!! Now hurry up and get that rear done!!! Awesome job tho!!!!
+Charles S. Barcus lol. This stuff is a ton of work!
What did you think about this plasma cutter. Is it any good?
It really didn’t work that well.
I’ve got a 79 Ford kingpin I want to put on my jeep. You think that bolt sucked....well whoever had mine welded the head of every upper and lower kingpin bolts(no idea why). So it took me forever just to get it torn down. It’s gonna be a pricey build because literally everything but the housing is trash but should be awesome when finished. I just need to figure out what to do with the rear now
What do you mean the kingpin bolts? You mean the lower kingpin cap? Cause those sucked!! Lol
Did u have to use a case spreader on the housing to get carrier out?
+pra3t0rian no I didn't. It was easy to get the old differential out but tough to get the new one in.
I like you video but your install was not to what the manufacture recommends. You need 0.010 of preload on the carrier bearing, and a case spreader to install. The backlash on the ring gear should be 0.006-0.010
+Mekhanic1 I know. It isn't done yet. Also the manufacturer instructions that came with the locker did not dictate a case spreader. They said to remove carefully with light pry bar which is what I did and it came out very easily.
Also this is my front so not as concerned as I would be for the rear.
What’s the width between your coilovers Trying to make sure that they will fit my 94 blazer
I’m Wanting to make sure the mount for the coil over shocks on the axle are positioned far enough to the outside of the axles to accommodate for the width of the 94 frame
not sure what you are asking. I have them mounted as far out board on the axle as I can. Basically the width of a dana 60. Seems like the axle would be the limiting factor not the shocks.
I'm curious since you went to coilovers why not adjust your pinion angle why you have it apart?
+STEVEN FLORES because that would change my castor too. And the spring pad on the Dana 60 is built into the housing and the ORD kit keys into the housing.
Merricks Garage well the caster could be changed by rotating the housing but if the Ord bracket cannot be adjusted then I guess your Stuck with it where it's at.
+STEVEN FLORES that's a lot of work for a pinion angle that is really that bad, only comes into play when in 4wd and gets better and better the more into your travel you get. Plus the ORD bracket makes it a moot point
Yes it is alot of work. Just looking for your opinion. Im building my sons 74 and its got 11" of lift, the angle is pretty bad. Not sure if we are going to lower it a bit or adjust the angle. How did your smog go? I may ls swap an 84.
+STEVEN FLORES well the 11 inches is your problem there. Try and lower 5 inches and move front axle forward and trim. I moved it forward an inch and that helped a lot.
Great Vid .. Thank you. I was trying to figure your accent out.. is there some Irish in it?
PS. Maybe some slow mo action under the truck going over some big stuff in the outro... Glad i came across this !
West Midlands mixed with some cali
14 bolt next?
+Dudes on Bikes yup, once the front is in and sorted the rear gets torn down
What gear ratio are you running?
4:56
Good video, good length. I appreciate you getting more into the grind. just out of curiosity, why did you have your buddy TIG those brackets on?
he likes TIG, did you see the knuckles he did for me? Crazy
You sure do love that face time with the camera! Even trying to add some hands on video time you managed to still have alot of face time. Don't get me wrong, i like your videos but we want to see full hands on from start to finish with no editing. Show the good the bad and the ugly. Great build by the way, i sure am jealous!
+STEVEN FLORES I think that is what I am gonna do livestream on.
How much did that cost
What part? Locker, hub, axles, knuckles and small parts prob $5k
Very good video buddy more detail next go around...
I'll second that. Great job!
+Kasey Voogt I'll try. Do you mean more explaining of what I am doing or just more video of the actual work. Filming the work is soooo tough cause I just get wrapped up in what I am doing.
More work plus the amount of detail you put into it and explaining first hand. You just can't beat context like that. I have been watching from the very beginning and have bought stuff from your Amazon store also.
Wtf it's Sunday and no video, 2 days late Gus's i got to work on my rig instead of watching, mr. 1/4" armored plate!!
+350anthony lol. Go get it.
awesome video man! really makes me anxious to start my k5 build. Gotta get my wallet a little fatter though before I can do what I want to do.
I love long videos and you will get better revenue off of them, too.
+mimixownzall yea as long as RUclips doesn't flag them. For some reason when I uploaded this it got tagged for inappropriate content and I had to request a review from RUclips before it would be monetized. No idea why but that is why there are no ads.
Merricks Garage Yeah, RUclips has seemed to take the insurance company approach. They deny first and then make you fight it hoping you will forget or just not do it. A lot of vloggers are getting demonetized but winning their appeals.
Good work! but thing that impress me more its How people with house and children can afford all this expensive stuff??
budgeting, 5 year build and determination. Plus selling and buying on craigslist.
4340...not 4130 .
Lol that is my mountain biking coming out. Back in the day 4130 was the chromoly to have for steel frames lol
Merricks Garage Are those Yukons still too fat to fit through the knuckle without shaving or installing with knuckle off first ?
No they fit. Tight but they fit.
THe length of the video is fine but the volume needs to be normalized. You voice is low and your music is loud.
You spent all that time tearing it down why wouldn't you just weld a truss on it
Nice.. Now the Driveshaft in front on full droop is gonna be fun...
lol, are you talking about my propensity for breaking them lol? Hopefully with the new ag shaft I have down there I should be ok. I am sure I have a weak link somewhere that I am overlooking though.
Great video man
What gear ratio are you running?