35 spline Dana 60 full float upgrade

[vandiesel]

I’ve seen broken axles on a semi float and heard a few tales hear of full float broken axles. I had been planning this upgrade after following another before me on expo. I finally got all the pieces and started today. I thought these pictures of my bearings would be good to share.

[vandiesel]

Here is what failing gears and bearings look like. I’m very lucky to have made it back from Death Valley to Portland.

[vandiesel]

I went with the cut to fit Yukon axles and revolution gears. The 35 spline axles slide right in my housing and make this a Dana 60 HD I guess. I plan on running Lucas 80-90 Dino gear oil. My van is a 4:10 and now I have 35 spline stubs up front and 35 spline rears. I’m sure sportsmobile had to make all sorts of decisions n these specs but still never understood the small front axles. Dynatrac told me they are the only customer the have that did this. Not sure if that’s true but it feels better having bigger margins on a rig this heavy.

[Twoxentrix]

Originally Posted by vandiesel

...but it feels better having bigger margins on a rig this heavy.

[JoeH]

Originally Posted by vandiesel

I went with the cut to fit Yukon axles and revolution gears. The 35 spline axles slide right in my housing and make this a Dana 60 HD I guess. I plan on running Lucas 80-90 Dino gear oil. My van is a 4:10 and now I have 35 spline stubs up front and 35 spline rears. I’m sure sportsmobile had to make all sorts of decisions n these specs but still never understood the small front axles. Dynatrac told me they are the only customer the have that did this. Not sure if that’s true but it feels better having bigger margins on a rig this heavy.

I never understood this either. Even the front dynatracs going in jeeps are 35 spline.

I went with Dutchman 35 spline on my rear D60 when I swapped from SF to FF. Also, new Dana Spicer gears but I went with Lucas 85W-140 dino gear oil. I think on the recommendation of ARB since I also added an air locker. Or, maybe it was dynatrac.

Glad you made it back before complete failure!

[vandiesel]

I’m making progress. Picked it up today. Ordered new stage 8 locking flange bolts and am powder coating my revolution diff cover with hammer finish. Hopefully when I’m back from biz trip this weekend my springs and brackets will be done at Oregon auto spring.

[vandiesel]

Pics for reference





Had to use a sleeve to help pinion seal. Probably would have been fine. Also the trutrac loses the “stuffer shims” that fills the gap. The mesh looks perfect and we found the bearing nuts I just put in on the hubs were loose and fixed that.

[vandiesel]

Some stage8 bling

[Twoxentrix]

There is always something sexy about shiny new parts/hardware mated with older used parts!

[vandiesel]

Cooking up some powdery goodness on my diff cover.