Dana 60 Gear And Locker Install

In this video I show you how I regeared my Dana 60. This axle is from a 2005 Superduty and will be going into my Jeep Wrangler. This is a very complicated process and can be different for each install. This video is not a step by step instruction, but more of a means to help you decide if you want to do it yourself. Check out some more info online and do plenty of research before trying this yourself.
www.pirate4x4.com/tech/billav...
My final Specs:
Pinion Preload - 25 inch pounds
Backlash - .008”-.007”
Gear Pattern: Good haha
Be sure not to skimp on any steps! Make sure bearings are fully seated and lubed with gear oil!
Part numbers will be posted soon after I drink my coffee
5.38 Thick Cut Gears : amzn.to/2WRSF7t
Zip Locker 4.10 down Case (for thick cut gears) amzn.to/2UpzzJg
Master Install Kit amzn.to/2IhFNn0
1/4NPT tap amzn.to/2IqapTk
Calipers amzn.to/2WUzSIU
Dial Indicator amzn.to/2UIDyzP
Yukon Bearing Tool amzn.to/2C6O6yj

[@spoolinX3]

Man, I think I’ve watched this at least 10 times. My 60 is just sitting there pulled apart awaiting to be re-geared. I’m 1 ton swapping and stretching my TJ after a nasty roll over. I’m getting so overwhelmed with everything and not having a single friend to help out sucks. I appreciate your videos man!

[@housegoth]

I love these videos! Very informative and you aren’t afraid to leave your mistakes in the video, it really shows the capability of a home mechanic.

[@irzoro]

Thank you for being honest and showing your human like the rest of us! You were good in explaining the how's and whys as well as showing that setting up a Dana 60 ain't no walk in the park! Well done!

[@ryanknapp4964]

Great video, thanks! It was exactly what I was looking for. Not glossed over like so many other shows

[@jorgelrod]

I run Zip Lockers front and back, they've never failed me when I've needed them.

[@unwrangler11]

Great informative video. You really put everything in plain language making it easy to follow. Thanks

[@swarbrickjesse]

That's dedication man. I don't think I would ever do this on my own, so props to you! Very informative and I'm learning alot. Also that hikeit is amazing. I get quicker RPM downshifts but the damn Jeep still moves like a dog lol. But definitely better than stock. Thanks again for that promo!

[@Them_Blue_Jeeps]

Its about time someone made a video. Thanks for sharing some knowledge!

[@gw33]

Finally, Someone who explians Backlash, Preload and drive patteren!! AWESOME VIDEO THANK YOU !!!

[@BadKarmaFab]

Going to start regearing my SD60 in the next few days. I have no doubts that this video will be instrumental to my success. Thanks, fam.

[@kylescaggs]

Found this because I have a Superduty Dana 60 for my Duramax, you're giving me some more confidence to try putting some 4.88s in.

[@davelebo6412]

Great series man. Thank you for taking the time and going through all the steps. Best part " I didn't mean to flip you off" within 30 seconds does it again haha... Great videos man keep them going!!

[@asperbergers7136]

I watched this before I regeared and installed my locker last year. I still find my self coming back and watching this though. Great video

[@cdmc012599]

Thanks for your time and effort you put into your videos

[@JKGearandGadgets]

Thank you man!

[@comanchefun1612]

I just picked up a set of 09 sd axles this weekend. Starting tear down, and this is a very helpful vid man. I’ll likely go with Yukon as well👍🏼

[@clintmcjeepjunkie820]

Headed to pull axles at a junkyard in Nashville next week. I'll be at your doorstep looking for help shortly after that 🤣

[@twinner666]

This is going to help me when taking my Salisbury apart. Thanks!!

[@BillyTpower]

Good video, glad my freezer trick worked for ya.

[@DavidCostan]

I don’t know how this doesn’t have more views. This was a great video

[@mapquestHs]

Super helpful video!! I’m thinking about tackling my gears on a set of superduty axles. Thank you..

[@brianalberto5662]

Thank you for everything you do!!

[@joesigrist633]

Great video! My rear UD60 starting making noise during acceleration and coasting. The gear oil was heating up and blew the pinion seal. Threw oil everywhere. Drained it and it was almost grey with metallic content. The pinion had little to no preload. I could jiggle it by hand. Not sure what happened but I am going to tear it down and probably do a rebuild kit depending on how the ring and pinion look. Probably going to order a new set of gears too because I am sure they have a bad pattern worn into them. Just Empty Every Pocket... fantastic video! I'll be using this for the front junkyard swap I'll be doing 👍

[@puckerfactoroffroad1326]

Great video! Way more detailed in the gear setup then the gear companies make! I've only regeared two jks. One rubicon and one sport. But for the setup bearings I put the new races in the housing and then made both old pinion bearings into makeup bearings and was able to put the shims where they were originally and pressed the new bearings on when it was all set up. Im not sure if my way was the right way or not. But I haven't had any issues yet. Anyways. Great vid and keep it up! If you're ever up near Michigan you'll have to make it to Drummond island for some wheeling!

[@rino11221]

I’ve been waiting for this video for so long lol

[@peterpazzanita3962]

Wow. Just watched the whole series on this one ton install. Amazing stuff. You just encouraged me and gave me the confidence to do the gears myself. Really nice job!

[@JustinKingOffroad]

outstanding video. having re-geared my jeep (friend who is master mechanic let me do it with his supervision) it's a fun but long job. and honestly not that hard. it's just time consuming.

[@TheTexasjsz24]

Really enjoyed your video sir. Liked that you made mistakes and kept ot on the video. We all make mistakes and need to see others make mistakes as well. Appreciate it.

[@jackreece2414]

Absolutely love this series, Ben! Awesome walk-through and TONS of information! ;) Keep up the fantastic content - I always get a smile when I hit the interwebz and see new stuff from you!

[@felixdeshawn4439]

I dont mean to be so off topic but does anybody know of a trick to log back into an Instagram account..? I was dumb forgot my password. I would love any help you can give me.

[@wilsonlucca554]

@Felix Deshawn instablaster =)

[@felixdeshawn4439]

@Wilson Lucca thanks so much for your reply. I got to the site thru google and Im trying it out now. I see it takes a while so I will reply here later when my account password hopefully is recovered.

[@felixdeshawn4439]

@Wilson Lucca It worked and I finally got access to my account again. Im so happy! Thanks so much you saved my ass !

[@frankmartin806]

Very cool you made it look easy

[@stuartmaitlen7618]

I like your style...thanks! Three foot long brass rods are available at home stores that might work well for race removal.

[@Offroad_Josh]

Great video! Thanks for making this.

[@johncranfordpersonal4146]

Very informative, great job.

[@Dallas-Rife-UDX-347-Tennessee]

Dang I set through this whole thing cause I wanted to see how you snaked that copper air hose through the fitting once I figured out it was an air locker !! Good video !!

[@cjstites1936]

Great video man!

[@Sharingxp]

Awesome videos man, Thank you.

[@jpeterd92]

Lmao," I don't want this to be another hour and a half video I wanted to be quick and helpful..." I thought wait how long this is video I paused it and looked an hour and 13 minutes lol Love it

[@mannyman84]

Thank you so much. Helped a lot

[@cajunmaker6917]

Amazing video, though. Thank you. I have the sterling and super 60 I will be rebuilding.

[@kfoneal]

If your going to be at the Great Smokey Mountain Jeep Invasion 2019 in August, I'd like to buy you a beer, Sir. Looking forward to it.

[@wazheamadman6086]

Awesome video mate very informative sucks having to use shims for back lash

[@Ks-zz9lh]

Hey thnx dude. Great videos love ur style. Liked and subbed.

[@Channel_1728]

I think that pink Jeep needs a Dana Swap! lol (great series super good)

[@yotacody]

I know you've already done it and its not the best way to do it but your brass drift being to short can be extended using a socket that the drift fits in and a extension. Video's are great man. Video's being long your being detailed and showing tips and tricks so if anyone gets hung up they can figure it out

[@toyotaholics2690]

Awesome video! Is there anything wrong with running the shims behind the bearing on the pinion side like your doing, instead of on the outside of the bearing like the ones ARB provides? I keep bending the shims when i drop in the carrier... Thanks!

[@gazay7777]

Very informative. Way over my head though. I did gears on a Chrysler 8.25 in a XJ once. Never again...

[@stoprez2006]

I know it has been like a year and a half since you did this but I am just getting into installing some 4.56 gears and a Torq locker in my 08 Super Duty 60. Can you shed light on why you moved the shim for pinion depth from behind the bearing on the pinion to behind the race in the housing?

[@isaaczuniga6654]

I’m keep watching this! So helpful Have you ever think on doing an 5.7 Hemi VVT swap in to your Jeep? If so I will be ready to take notes I’m in the process on mine

[@JKGearandGadgets]

If I do an engine swap it will probably be a Ls swap. It’s sitting in my mind... lol

[@isaaczuniga6654]

Did you have Facebook bro? And yeah LS swaps would be fast, but did you want being faster or more torque ? 🤔 I will said LS swaps are for drag racing or drift and for off-road I will said hemi I mean dodge Jeep? 👌🏻 they match

[@JKGearandGadgets]

isaac zuniga yeah man join the FB group (JK gear and gadgets - the group). I prefer Ls swaps because they are lighter and easier to fit

[@jcull]

Great Video Ben! I’m thinking of just adding a rear locker to my JK and not rear gearing. Would I just have to make sure the backlash is in spec without changing any of the pinion shims?

[@JKGearandGadgets]

Yes you will have to check everything, and possibly readjust backlash and pinion depth

[@davesinnett2977]

Did you go with a thick cut ring or regular? On Amazon the 3-35 Yukon Zip locker was cheaper then the 4-35 so I was thinking of getting the 3-35 and using thick cut gears. Anything wrong with that?

[@Swilk1890]

So are you going to swap your JK axles into the LJ... that would be another good video series!

[@patriotintheso8707]

Great video thank you very much

[@Sniperssx]

for oil what type of oil should add slipr oils as well also gasket should put a silicon or gasket

[@picaso340]

Did you just recently get your shirt? I know it was a January thing but I can't find it anywhere now. ("We don't need roads!")

[@socalrunner08]

What size brass punch would make this easier so I can purchase one.

[@r1grover]

I know this is going way back but my question is what did you end up doing in regards to the wheele stud size and thread on both axles. Did you set them up with matching studs? What did you go with? Thanks for all the great videos.

[@roberts5118]

One last thing. When you install the washer under the pinion nut, don't put oil on the back side, put RTV sealer so oil doesn't leak out around the splines.

[@JKGearandGadgets]

Not entirely needed with a high pinion axle with a positive pinion angle under the jeep. On transfer case yokes and low pinion axles, yes it’s more needed since the splines can leak fluid.

[@roberts5118]

@@JKGearandGadgets No that's incorrect. Pinion angle has nothing to do with it. The fluid is sloshing around and completely covers the pinion gear regardless of pinion angle. It needs to be sealed, regardless of pinion angle, unless you're not planning on driving it and leaving it sit there.

[@roberts5118]

@@JKGearandGadgets there's no such thing as "more needed to be sealed". It's either sealed or it's not sealed. Your tires are either sealed and hold air or they don't lol

[@JKGearandGadgets]

Robert S it hasn’t leaked one drop. Drove across the country twice, wheeled here in VA, Windrock Park TN, NC, Johnson Valley CA, Bigbear CA, sand hollow Utah, etc.

[@JKGearandGadgets]

Robert S haha I’m not here to argue. Sure it’s a good idea to always do it, but on a high pinion it’s not exactly needed. Look at all the factory JK front axles, high pinion, no rtv... no leaks through the splines. A low pinion axle will have a higher chance of spline leakage. For example, I just regeared my Jeep gladiator. Do you think there was rtv on it from the factory? Nope. Did it leak? Nope

[@Arykperry]

What did you do with the vacuum port and breather port ??

[@phillmellina]

Fantastic.

[@dabofiron.itzsimplicity]

Dude thank you

[@JKGearandGadgets]

Glad it helped!

[@azimutazimut3165]

question.. why did you go with the Zip Locker that is 4.10 and down + Thick cut gears VS the Zip Locker 4.56 & Up + normal gears? Thanks!!!

[@Rajavampir999]

I have toyota grand innova 2012, can it make a lock diferensial??

[@roberts5118]

That would also involve pulling out your carrier one more time so your only measuring the force it takes in inch pounds of the pinion turning and not the additional force it takes of the pinion turning the ring gear and carrier.

[@shua242]

Liked b4 watched, wanna see your KZbin blow up to the next bleepinjeep

[@JKGearandGadgets]

Thank you!

[@isaaczuniga6654]

He got more views than them actually 👌🏻💪🏻

[@mazevx2451]

Ben isn't annoying like others... That's probably his biggest advantage! Putting out a video when it's done not forcing 2 crap videos a week.

[@vanwaggggg]

Getting ready to do my build. Looking for info on the air line port. Mounting in front of the truss makes me nervous about exposure. Would mounting behind the truss be an option? Feel like that would be better protected

[@JKGearandGadgets]

You could try, but I don’t see how. Thousands of people are running it like myself and have no issues. You could always fab a protection plate for it or something if you worried about it. But I don’t see any drawbacks or potential issues with it on top.

[@Sniperssx]

the dana 60 you were working on simple as 3 links am right ?

[@darianmiller6831]

What did you do about having two axles with different lug pattern?! I have a 14 bolt rear, planning on getting a D60 but it is slightly different pattern. Don’t really want to have to carry two different spares around.

[@JKGearandGadgets]

Rear spacers adapters. The rear axle is 3” narrower, so 1.5” adapters work perfectly

[@micahhaislett3792]

Did you find the o-rings when you moved?

[@adamsorell4851]

i have a cdi dial torque 3/8 0-300 in/lbs will that work or do i need 1/4" wrench??

[@JKGearandGadgets]

That should work. As long as it’s accurate on the lower end

[@joewilkerson3444]

Great video, but a little too fast in some places. The scenery was great and I have never heard of this place before. I guess everyone is hung up on Black Bear Pass. Thanks for the new scenery.

[@JKGearandGadgets]

I’m confused. This is a video in my garage lol

[@d7k8gsxr600]

Watched the video like 10 times so far so I know what to do with me axle. A couple of questions: When doing the initial pinion preload setup, what torque are you setting the pinion nut to? What other parts do I need for a sterling rear axle in regards to the yukon bearing puller? Why did you not do a pinion depth reading? Extra step or is not really needed for this dana 60 axle setup?

[@JKGearandGadgets]

Don’t worry about torque #s on the pinion nut. It depends if your using a crush sleeve or a shim setup. Crush sleeve setup, you will need to focus on pinion preload, as it changes with the amount of torque on the nut. With the crush sleeve eliminator (or shims), just tighten that sucker down

[@patrickhickman8723]

what about inner axle seals?

[@reuben649]

Are you going to have to change the factory transmission and drive shaft? if so what will you be going with?

[@JKGearandGadgets]

Transmission is fine, but will require a custom driveshaft. That will be an upcoming video

[@rockynixon3832]

Pinion pre load is measured by torque to rotate the pinion. Carrier preload is measured is measured by total torque to rotate of pinion and carrier together.

[@JKGearandGadgets]

Negative, carrier preload is how tight the carrier sits in the housing. Ttr is still pinion preload, just another spec

[@rockynixon3832]

@JKGearandGadgets you subtract the TTR torque to rotate (pinion preload) from the TTTR total torque to rotate(Pinion plus carrier pre load), which gives you the carrier pre load. That's what Dana says, anyway! That's how I set mine up, and so far, so good.

[@BostonianBroker]

Will this same axel for an 01xj?

[@adamsorell4851]

hello. i just want to change ring and pinion.is going to be pia? someone told me if im just changing ring and pinion to swap it and put it back together. measurent will be ok??

[@JKGearandGadgets]

No, this is what you have to do to change the ring and pinion

[@adamsorell4851]

everything i read says to start with original shims. of i do that will most of the time that work? lot of tools$$ need to be bought for this.im just going from 3.73 to 4.88. in a 99-04 superduty 60 to make my f550 4x4. i read that the d60 axles and tubes on the f550 d60 are inch longer on each side. if if that is true doesnt make much sense. can you confirm?

[@raymondw7875]

Is the Dana 70 the exact same process?

[@ryanmaestas8005]

I like that you didn't cut out you forgetting the shims. Us humans make mistakes all the time lol

[@raulriveracrazycat5959]

Hey Ben, how you doing. I wanted to get your opinion on lunchbox lockers. I have a 2017 Jk sport that I'm building up on a budget. I live i Harlingen Texas so the only wheeling I've done on it is at SPI. I put a 2.5 in lift on it with 35s. I'd like to take it on trails soon but without lockers I'm a little nervous. I just don't have the budget for air or e lockers. So your opinion would be greatly appreciated. Thanks

[@JKGearandGadgets]

The 2012+ auto trans does not like auto lockers and will go into limp mode. Generally I would stay away from lunchbox lockers on a daily driver

[@raulriveracrazycat5959]

@@JKGearandGadgets awesome thank you

[@miketurd]

You rock

[@williep5161]

Subscribed

[@jeremyrios6575]

Whats the MPG expected from the 1 ton swap?

[@JKGearandGadgets]

We will see!

[@jeremy8715]

Would I want to reuse the factory shims that are between the carrier and the bearings?

[@JKGearandGadgets]

Yes you can, or just duplicate the shims with new ones

[@JKGearandGadgets]

Those are what will adjust your carrier preload, and moving the shim totals from side to side will be adjusting your backlash

[@evo2racer8029]

Why can't you use the new bearing races when testing with the set up bearings?

[@evo2racer8029]

Never mind you answered my question right after I sent it. Lol hadn't finished the video yet

[@J.A.S.E.alaventure]

you checked your work more often and with greater attention than the company that made the primary mirror on the hubble space telescope 🤨 they could learn from you :)

[@dicktomasko1553]

Supposed to use a case spreader. Also supposed to be hard to get in with a spreader.

[@JKGearandGadgets]

Case spreaders don’t work so well on trussed axles. This setup has been working perfectly fine for about 15k miles so far

[@blakkkatt9]

Will axels from a 2015 f250 sd work?

[@JKGearandGadgets]

The front yes. Rear won’t work on a JK without a lot of extra work and moving the gas tank

[@Free_and_accepted_]

Watching you use your rubber mallet is like watching Bob Ross clean his paint brushes, "just beat the devil out of it". You can tell it kindles joy..

[@Mikeywatches]

How the 5.38 treating you? How many miles you got on them ? Keep reading that they are weak and i should go 4.88 not sure if thats true.

[@JKGearandGadgets]

Holding up perfectly fine. For a Dana 60, 5.38s are hard to break without a lot of horsepower

[@andrewmccarthy4144]

When showing the contact pattern, next time can you hold the camera still so we can see the pattern for a little longer? Thanks. BTW, this is my go-to set-up video.

[@lords2112]

your bearing caps are marked already ..tmhatss what the p is stamped on the case for....

[@Basri_kaplan]

"I'm having a hard time getting in there with my hammer" me too man, me too :/

[@DrGand]

Is it the same procedure for a 80s Chevy D60?

[@JKGearandGadgets]

Pretty much, however you will need to use the pinion oil slinger, so same thing as measuring the battle (Measure old vs new and make up difference in shims)

[@DrGand]

Makes sense, thanks for the upload! I'm gonna be tackling the job on my '87 K10 on 1-tons.

[@MHB7000]

That's 1340 x 2 right?

[@zxtuner4lyfe]

So how did you fix castor with junkyard axles?

[@JKGearandGadgets]

It has more caster than the jk axles. 10* of separation. I’m running 7* caster

[@zxtuner4lyfe]

@@JKGearandGadgets next question bed. I see you didnt use the pinion oil slinger... whats your rational?

[@zxtuner4lyfe]

@@JKGearandGadgets next question bed. I see you didnt use the pinion oil slinger... whats your rational?

[@jonpena714]

What did you use for ball joints?

[@JKGearandGadgets]

Mine were in good shape, reused them. But I would just go with standard replacements if you need to change yours

[@jonpena714]

You have any recommendations? I've read that moog are not good.

[@jaxgsxr]

What bump stop extensions are those?

[@JKGearandGadgets]

im not sure what your talking about?

[@jaxgsxr]

@@JKGearandGadgets The one mounted on your front axle truss.

[@JKGearandGadgets]

They are part of the truss swap kit

[@jaxgsxr]

@@JKGearandGadgets Nice! I used the Artec 1-ton truss kit and mine only came with perches. Nothing like yours. Your setup looks great, man.

[@valrodrigues4203]

Ever had stalling problems with your jeep

[@JKGearandGadgets]

I have not with my Jk

[@johnnettles8867]

I need an Excedrin

[@JKGearandGadgets]

😂

[@NarleyAdventures]

I need a double shot myself.

[@brianduff4278]

Wish I didn't get drunk and fight my buddy that I was hoping to help me with this. I'm over me damn head. Damn it!! Easy taking the old axle off. But now I don't have a front axle so I can't even get it towed. The front is facing a wall. Lol I'm fuked.

[@Mohamedseddek]

♥️👌👍