Dana 60 rebuild

[Billydelrio]

I recently rebuilt the 23 spline suregrip in my Dana 60 along with a gear change, and have the following notes. Nothing good/bad, just notes.

Upon the disassembly, I found the spider gear pinion shafts galled and the clutch plates wore just a bit. I replaced the pinion shafts, but the new shafts did not have the axle endplay pin. I thus used the Moser 9400m nonadjustable axle bearings.

I checked the pinion depth of the 5.57 gear before removal and found it to be close, but a wee bit deep by my measurements.

Installing the 5.13 gear: The Dana case was machined .021" shallow of centerline, so I subtracted .021" from the gears indicated requirement of 3.129" to get a measured depth of 3.108" from the cap mating surface. I was able to get 3.109ish. After a few ins & outs, pinion preload was set. (thank you impact wrench!) The ring gear had a few thousandths runout, not enough to worry. I put a total of .089" shims on the ring gear carrier and adjusted to .005 - .007" backlash. My case spreader allowed me to finally tap the preloaded assembly into place and I torqued the cap bolts.

Time will tell if it was done correctly!