Dana 60 Swap Kit Install - JK 1 Ton Swap Episode 5

Welcome back to another episode of the JK 1 Ton Swap series!
In this video I weld on the Barnes4wd Swap truss onto the Superduty Dana 60. It is a fairly straightforward process, however it does require a lot of welding.
Check out the kit, www.7slotcusto...
Current price list:
Front Axle: $500
Rear Axle: $100
Grinding Supplies: $50
13 Bolt Shave Cover: $190
Barnes4wd Rear Swap Kit: $391
Barnes4wd Front Swap Kit: $399
Magnetic angle finder: amzn.to/2UDyp8q

[@JKGearandGadgets]

Ok I have no idea why KZbin just added music into my video.. let me fix that real quick. It wasn’t there when I posted the video and just randomly started a few minutes ago. I will work on a way to get rid of it! Update: KZbin removed the music. All good now!

[@JKGearandGadgets]

But then again I just realized my hand moves to the beat for the few seconds lol. Wow no idea what happened there. Hopefully those first few minutes of talking revert back to original audio soon

[@owilde64]

@@JKGearandGadgets HA I thought my laptop was running something in the background. Or you've been in-hailing too much Steel-it..

[@jeremy8715]

I'd want to see a video about welding to the cast diff.

[@picaso340]

@@JKGearandGadgets Ben, if you figure it out (find out what track it is). LOL

[@adamaldinger6960]

Well then thought that was a little weird lol

[@justinschultz6857]

Make the cast welding video!! This is by far the best series on a one ton swap and skipping that would make it incomplete. I’m loving these videos.

[@JKGearandGadgets]

Working on that video currently! Figured I had to do it lol.

[@Thexkidd]

Barnes should be sponsoring you.

[@nelsdemma6907]

would like to see that cast weld

[@JKGearandGadgets]

Working on that video now!

[@chuckwalker957]

Love the crocs in the logo. easily the best part of the channel. Personally I dont think I could have done a single upgrade to the jeep without my camo crocs

[@whywoulditellyoumyrealname4598]

The best part of your welding is that you did it without managing to burn the place down

[@swarbrickjesse]

You're doing a solid job bro. Better than I would've. I can't wait to see them mounted up

[@markbellger8945]

Love these videos! You go in depth just enough.

[@emilyhayton8392]

Mark Bellger that’s what she said!!!! 🤣

[@JKGearandGadgets]

Omg 😂🤘

[@bayouboattrash]

Yeah man, that would be a great video for welding cast. If you've gone this far with the series, you should go full bore with it. I'm enjoying the series so far!

[@shawnsolar4724]

0:50 crocs and wrenches instead of skull and crossbones. I love it

[@MSTrishRN]

This is a great series. I plan on doing 1 ton upgrade in my jku in about a year. I thought i would have to get someone to do the work for me or buy the axles new. By you doing this I am starting to think I can do this myself.

[@emilionides5520]

Those safety shorts go really well with the crocs in your logo. This is a really great series.

[@apexpredator_jku]

LmfaOo. OMG...I can't believe you actually used that Logo!!

[@JKGearandGadgets]

Bro I love it 🤘🤘🤘🤘

[@JsGarage]

What logo?

[@apexpredator_jku]

@@JsGarage Intro of the Video at 0:48 seconds in

[@jamesmoore1124]

ApexPredator_JKU crocs are making a comeback and they are comfy!

[@apexpredator_jku]

@@jamesmoore1124 no need to sell me on them, I'm a fan...have 4-5 pairs myself

[@admantiom1848]

When the time comes, get the “OX” locking differential, Lockers are made of 8620 forged and heat treated. SAME AS RING AND PINION GEARS and USA 🇺🇸 made and I have it on my D60 and there is nothing like it.

[@michaelhance9433]

So stoked to see this on the trails. Live close to Uwharrie. So see you there some time. Love all your videos.

[@hivoltagedriver]

You talked about steering a little. I was hesitant to run rod ends on my daily driver. I stayed with the factory Ford style on mine, but upgraded the tie rod and drag link to heavy duty versions from Precision Metal Fab. I also used Moog upgraded tie rod ends. If I break a tie rod end, I should be able to walk into a parts store anywhere in the country and buy a replacement.

[@jeepn8048]

Another vote here for making the video on welding the cast .

[@jeepn8048]

Ive stick welded cast . Ive have plenty of welding time in with a mig but ive never used a mig to weld mild steel to cast..

[@JTwelder.]

Definitely want to see you do a video on welding mild steel to cast!!!

[@allanjames6628]

There is a lot of info out there on welding to the cast, but I’d like to see your explanation. Definitely wanna see you put them under the Jeep and see how well everything lines up and fits now. Awesome video series man. 🤟💀🤟

[@kevinm.counsellorjr.5753]

I don't have a jk and i don't plan on doing a axel swap anytime soon, but I still enjoy watching these videos

[@shua242]

Canola oil works great as an anti rust coating on spots you can't spray. They also make a cast iron rod if you are an okay stick welder with any 60 series rod it fairly easy.

[@JKGearandGadgets]

Heat it up and make some popcorn on your axles!! 🤘😂

[@shua242]

@@JKGearandGadgets the nice thing is as you heat it it just makes the coat beater because it just sticks again as it cools, just make sure there's a hole so you dont make a bomb by mistake.

[@davidriggins1591]

Thanks dude...Binged watched...giving me confidence to tackle myself

[@bobrussell7644]

I'm really enjoying this series. Please keep 'em coming. And the haters can suck it!

[@Fishabug]

Another great video Ben. Making us Salvage yard 1 Ton boys proud! Built not Bought

[@bgrabe4590]

reading through comments. would seem the music is back. 0:49 - 2:45

[@JKGearandGadgets]

I’m about to flip. This is ridiculous... I contacted KZbin help and they managed to take it off. Now it’s back. Wtf 🤦🏻‍♂️. I don’t even know what song that is 😂

[@livelife8480]

Will be doing this swap both 14 and super on my own friend welder and your videos will get it done thanks for the information perfect with price and all

[@tomd1939]

This is quickly becoming one of my favorite channels

[@JKGearandGadgets]

Thank you!

[@mikem5831]

Great vid as always. The top pieces of my coil perches are still open so I can paint them first. Good catch. Just welded my tubes the other night, then got all the rear brackets on and working on finish welding. I knew going in what was needed to weld to cast but there really aren't a lot of good videos out there. Although most diffs are cast steel, if someone runs across cast iron diff housing, the need to use a nickel based rod/wire.

[@danhambrick6331]

Nice job Ben.Im in the process of a front and rear axle swap on my XJ.I dont have a Miller welder,I have a Hobart 190,but I think it will do the job.

[@JKGearandGadgets]

The Hobart 190 is a great welder!

[@adamaldinger6960]

Love the new intro Pic. And who cares what other people think. You are doing what you are pationate about and it's your jeep. Love the videos and I think your welds look pretty good. Following this one all the way. Cannot wait to see the gearing part.

[@roadhouzz4275]

Great video Ben, don't worry about the "he's not a professional" haters... You're how to videos make me want to take up welding and put these under my '07 JKU, keep up the great work

[@dominocweber9763]

Jk gear and gadgets super informational and cool series of vids. You have helped me confirm i want to do DIY dana 60 swap on my '14 wrangler JK. Very helpful but propably going to get in truoble with the wife lol

[@cdmc012599]

Another great video. Really think it's awesome that your doing this series, very helpful for the average DIYer

[@iamnoone5248]

Learned alot. Def doing this soooon

[@dylanl4869]

Awesome! I would like to see the process of welding to cast

[@danhampton4861]

Thanks for the videos man. I am in process of doing this swap to my XJ I went with the 14 bolt rear as well. Thanks for all the good info

[@benson8686]

I would like to see you weld to the cast. I think the series wouldn't be complete without it.

[@bandboffroad5743]

Good job man very informative. And yes the video on welding to cast is a good idea.

[@coletonfrench8308]

Awesome video!!!! It was super helpful for me I am going to be doing the same thing to my Jeep I already have some heavy duty axles now just need to order the Barnes trust kit!!!😊😊😊😊

[@ctrlnull5308]

thanks for the videos... i was on the fence about upgrading 30's buying front 44 or just do this set.. while i only plan on going from my 33's -> 35's next year.. i think ill go ahead and invest for the future

[@JKGearandGadgets]

You won’t want to do these axles if you plan on 35s. One tons need 40s or 42s in order for it to be worth it

[@ctrlnull5308]

@@JKGearandGadgets dont tell me what to do

[@JKGearandGadgets]

Ctrl Null ok?....

[@videoparker28]

About the welding to cast...step-by-step baby, I would like to see it because i am "self taught" garage welder.

[@randywilliams467]

Enjoying your swap thank you very informative

[@Margaritoflrs3]

First two minutes of just music instead of you talking but seeing you are trying to explain something was great lol

[@JKGearandGadgets]

Wait what??

[@JKGearandGadgets]

Bro wtf lol. That was not there earlier!!

[@Margaritoflrs3]

JK Gear and Gadgets starts at 00:49 - 2:45

[@JKGearandGadgets]

Haha I just went and watched... somehow music got added onto the video on the YT editing program. Thanks for letting me know, must have just happened. That’s gotta go lol

[@Margaritoflrs3]

JK Gear and Gadgets no problem brother! Keep it up. I may do the same diy 1 ton swap soon

[@jtcusa7288]

Who would dislike this? A-holes that's who. Great job brother 👍

[@crawlusa505]

I am absolutely loving this series of videos! Thank you!

[@tomvanschaik4862]

Great videos and great info keep up the good work and I hope you cover the wheel speed sensors for the axles that is the part that worries me the most for doing this swap.

[@JKGearandGadgets]

Thank you! And no worries that will be it’s own video and I will talk about all of your options

[@Jeep79]

What a great job bro

[@JKGearandGadgets]

Thanks man! 🤘

[@mavjeepjk]

Good job man, can't wait to see it on tons! Definitely get the cast welding video!

[@ryalsoffroad]

you deserve way more subs, amazing series cant wait for the rest

[@JKGearandGadgets]

Well help out and share the Channel with your Jeep buddies!! 🤘

[@FPSNovaS]

I’d put grease fittings in the part ware you said it would rust from the inside out

[@mikehoffman3690]

The music intro was a bit of a surprise.Otherwise, very informative video. A bit more than I would attempt myself to tackle myself. Great information to explain the process and the specifics of the axle design.

[@JKGearandGadgets]

That music isn’t supposed to be there!!! Lol. Somehow KZbin added it randomly last night, I’m working with them to get it taken out. A lot of important info is discussed during that portion. That music wasn’t there when I uploaded it, nor the first few hours of the video being uploaded

[@bradleycollins8485]

I wouldn't mind seeing you weld to the cast. I don't mind seeing all the build. Plus if you ramble on I can fast forward!! Lol jk. I really like all your videos, except the light bar video. That was doomed from the beginning. Nobody's perfect! Keep up the good work man and jeep on!!

[@shua242]

My word!!! You're killin me with the time between!!! Haha good work bud.

[@leegreen7524]

Don't worry about what everybody else says doing a good job

[@JKGearandGadgets]

Thank you

[@fixstyle9244]

Great 👍 content man !!!

[@bender_gxor4092]

Love this build!

[@johndempsey8643]

Nice job Ben, please show us welding cast,

[@rareearthfab5511]

You have to do the cast weld. To not do it would be an injustice to the series and the people who are watching your video. I build a lot of axles and it is an important step to get right. The average hobby shop mechanic is unaware how to do it correctly or even why you do it. So have at it!

[@chrishurley9128]

I'd like to see the video of you showing how to weld to cast !!

[@douglaschristian2909]

I'm a xj fan and bought 78 Ford Dana 44 Ford 9in too full width my xj, I'll like your project, and want to see cast welding

[@Rick-4552]

I like to weld in shorts an flip flops!

[@AmazingBrando]

Look great! Awesome series.

[@strikeright54]

great video again. i agree do the cast by itself.

[@bryanmuck1651]

Awesome video Ben! Keep up the great work!

[@michaeloakes7997]

I would be interesting in watching the how to weld the cast video

[@bgrabe4590]

do a video of welding the cast. even if you just explain the process then do like a time lapse or something of the welding then show finished product

[@oldprophet]

Are we really 'n' control of our so called own channel? hmmmmmm, one does begin to wonder tho, " the music" U didn't add............. Other wise, great video, very valuable DIY info: Thanx again........

[@JKGearandGadgets]

For some reason youtube keeps automatically adding it each time I remove it... been talking to them about it and having a hard time. Very disapointing

[@Tsmace33]

Hey I don't know if you thought of this but you should make a video showing how to weld to cast. Hahaha 😂 Seriously though. I'll watch it.

[@manny1584]

Nice job keep the process coming. 👍

[@josephhernandez3346]

Looks good man thanks for making the video 👍🏻 I can’t wait to start mine

[@videoparker28]

I have an 08 i want to copy your builds on but i do have one question, Are you still factory engine? 3.8 or 3.6? With the weight of the axles do you need to do any engine mods to keep it moving with ease? And thanks for doing these. I am a videographer/editor by trade with a journalism/Documentary focus and I must say, you make it easy to understand and put together well. Keep it up.

[@JKGearandGadgets]

I have the 3.8 😳 but with 5.38 gears it should move just fine. With the 3.6 you would be golden. However we will see once they are under the Jeep lol

[@JKGearandGadgets]

Sorry I just saw you have an 08. So if you have the automatic it will be a dog, but a manual will be a lot better

[@Ty-tz4bs]

Will Ben add another one ton swap video? The world may never know

[@JKGearandGadgets]

😂

[@Ty-tz4bs]

There we go!

[@TheBeardedJeeper]

Lookin good man

[@jeeperxfinity5298]

Looks sick man!!!!

[@jackknutel1083]

Nice welds!

[@JKGearandGadgets]

Not the best, but good enough for me!

[@jackknutel1083]

JK Gear and Gadgets give yourself some credit! Not too shabby!

[@jasonbecker4613]

👍🏻 great vid!! Your my hero!!

[@rickketchumn4458]

Great job

[@jamesmarchel8386]

Great job once again

[@hunterwhitworth1271]

Show us how to make a cast!!

[@rodwood693]

Would love to see the cast welding vid :)

[@ryanbranch8046]

Love your videos! Helps a ton to watch these, way more informative than any other videos I’ve watched! I’m planning on doing axles this year hopefully, did you ever sell the d44 or do a giveaway?

[@RedRockCrawlers]

Coming along nicely. Installing a fully adjustable lift on my jeep I had to do a little adjustments of caster and pinion angles, Obviously not to this extent. Did you do anything about moving the shock locations farther away from the frame? Or will the width of the axle take care of that?

[@user-uu7qj6tm5n]

Hello, wonderful man. Please tell me the weight of this Dana super 60? Can not find. Thank, good luck.

[@greg2772]

What do you plan on doing with those Raceline beadlocks after you put the one tons on?

[@JKGearandGadgets]

I’m still not sure. Debating on moving the axles and wheels to the LJ

[@nickwinder2617]

Wontons!! I’m hungry now

[@Spyyyder1]

Hey Ben , really interesting video as usual . Might be a dumb question , but how does that work with doing some major DIY work on a vehicle with street legality ? Here in Europe , doing something like this would entail a nightmare to get everything checked out and evaluated so that it can be added to the vehicle papers and be street legal . Would cost at least another 2 grand also . Can you just drive stuff like this in the US ?

[@JKGearandGadgets]

Not sure about over there in Europe, but most states here it’s perfectly legal

[@mikejackman4416]

May have missed it...But are you upgrading power..?. LoTs of more weight ,, I realize gears are going to help

[@JKGearandGadgets]

In a few years possibly, but with 5.38s it will be fine. Sure it won’t be fast, but good enough for me!

[@mikejackman4416]

Cool just wondering

[@JsGarage]

I bet you're itching to get these on the Jeep.

[@JKGearandGadgets]

You know it!!

[@scottfletcher199]

Great Video! Are you back to work yet? Hope so...

[@JKGearandGadgets]

Yep!

[@scottfletcher199]

@@JKGearandGadgets Good News!

[@caroleertel2961]

Good job son 👍🏻

[@sambell8284]

Great video series...makes me excited to tackle this on mine. Eager to see how you get these to play nice with the abs and tcs. Also how the break pedal feels with the bigger breaks. Any plans for a bigger master?

[@JKGearandGadgets]

Yep!! All of that will be discussed in a video 🤘

[@brianfedie8046]

So, the lower control arms are spread out a bit wider than normal. Did you have any problem getting them on? I see that the Barnes site sells lower control arms with a 10 degree bend in one joint. Did you use them? Thanks! I don't need a 1 ton axle, but I've decided to do a build like yours instead of building a 44 to replace my front 30. Thanks! Love the content!

[@JKGearandGadgets]

I used Currie control arms in the front to make it work for a little until I did the 3 link. The Barnes offset arms are the best choice. What are your plans for the rear axle?

[@JKGearandGadgets]

Nevermind I forgot we talked about that in your other comment lol

[@millstonejeepworx]

Great video Ben. One question. Does the truss kit have have a spot to mount your Hydro assist? Or did you add that elsewhere. Not sure if I missed it. Thanks

[@JKGearandGadgets]

I just used the lower trackbar mount hole, but you could weld tabs on

[@millstonejeepworx]

@@JKGearandGadgets Thank you, appreciate it. I'm in process of collecting the parts. Have my front axle and starting on that. I'm going to build mine for 3 link from the start. Once axles are done I'll get 3 link kit and install the crossmember and frame brackets. Then swap them in. This way jeep is only down for the actual swap time.

[@bhanson82]

What did you do to avoid your Pitman arm hitting your tie rod? I did the exact same swap but now at full compression my Pitman arm hits my tie rod. I cannot lower my hydraulic bump stops anymore. Thinking maybe a longer Pitman arm might work but I wanted to check to see if anybody else has had this issue.

[@hunterwhitworth1271]

Where’d you learn to weld?

[@JKGearandGadgets]

Just started practicing and went from there!

[@mesomorfo]

Cast weld video?

[@JKGearandGadgets]

Will be posting it tomorrow or Wednesday! 🤘

[@mecanicomecanico5444]

I am buying parts for a project little by little, what vehicle uses dana 60?

[@dabofiron.itzsimplicity]

How did you set pinion angle ? Looks like you just arbitrarily slapped the truss and brackets on

[@JKGearandGadgets]

I talked about that. Caster and pinion angle are relative to each other. Weld it to favor both, and then you will use your control arms to dial it in when installed under the jeep

[@marineconceptsdetailing5558]

Hey man, did you weld the backside of the side braces in the back of truss or just in the front?

[@javicata9583]

Bro u the shit!!