The Dana 60 differential is a type of car axle that was widely used by many car manufacturers from the 1960s until the 1990s. For obvious reasons, many Dana 60 differentials are still in use and will require maintenance in order to keep them running. Should you find yourself faced with the task of rebuilding a Dana 60 differential, several tips will help to make your work much easier.
Disassembling the axle can be challenging. The spindles, which can become stuck, might require a great deal of force in order for them to come loose. You can exert a good deal of force without risking damage to the spindles by using wood blocks to absorb the force. Remove the rotors and the spindle nuts and place the block of wood beneath the spindle shaft, getting it as close to the end as possible but not so that it is on the threads. Then hit the block of wood with a sledgehammer. It may take several hits and several blocks of wood. You can also use this method to remove the pinion.
You will need a pressure washer and degreaser in order to thoroughly clean out the differential before you put it back together. You must clean all the grit out of the differential, as well as any debris that may be inside of the axle tubes. Once it is clean, blow it with pressurized air.
When you are setting up the gears, make sure to use the highest quality gear marking compound possible. It might be a good idea to go to your local dealer and buy the type their mechanics use, as most often, the gear marking compound that comes with the new gear will not be very good.
When you are finished rebuilding your differential, make sure to break in your new gears. You do this by driving in two-wheel drive with the hubs unlocked at a speed of around 80 kilometers an hour. After this, disconnect the rear drive shaft, let the differential cool for about three hours and then drive it at the same speed for the same amount of time, except with the hubs locked.
Buying a kit can be helpful because you can replace all of the bolts, seals, bearings, bushings and washers that might be worn out. You will have to buy different kits for the front and rear differentials.
