Alright, yesterday I went and picked up a Dana 60 out of a '79 D200 with a blown 318 at 120,000+ miles. I am wanting to do an overhaul and re-gear on it and have it set up so all I have to do is bolt up suspension and brakes. I would like to put 4.56 gears in it but from what I have read, the carrier break is 4.10/4.56. I have seen that there is ring gear spacers as an alternative to a carrier swap but I haven't seen any thick cut gears. Is there any downsides to using the spacer besides it being another part to break? As for the overhaul, I am assuming the rebuild kit is everything for the differential case and not the bearings and seals for the wheel hubs. Would those seal and bearings at the hubs generally need to be replaced or are they a lifetime part? I ask because I haven't heard many stories where they have been replaced. All input is appreciated.

 

I suggest you expect to replace everything. Especially if its been sitting for long time. If used enough to keep brakes from seizing, then maybe can delay that hardware assuming not obviously shot.

Dont do a spacer on the ring gear.

So this is a rear axle since D200 is 2wd. This going to be swapped in to your 2nd Gen? If so, then issue with speed sensor, springs, brakes, etc. Not all bolt up stuff.

Trying to understand the path is all.

 

I have a '95 so speed sensor is in the transfer case tail shaft, I am aware that spring perches will have to be moved or changed. I saw on one website that the oem replacements were 2 1/2 inch springs, just more springs in a pack. It has drums on it now, I haven't yet decided if i'm going to convert it to disc (I don't know a lot about the parking brake setup for disc). If I do stay with the current drum brakes, all abs parts are on the frame and not in the drums, right?

 

If you only have RWAL, just skip it. Remove/disable it. You would need a sensor, and tone ring on the carrier to make it work. The older rear has no provision for that, and making one work would be a major pain.

 

Did you happen to measure the axle flange to see if they are the same?

 

Ahh, ok great. No dumb VSS for you!! lol

If the OEM replacements are 2.5" leafs for that axle, then you don't have to do anything for your truck as they are same width.

I'd suspect the parking brake will differ just because it can. hahaha That part really depends on how custom you want to get. Changing to disks requires fab work as I don't think the brake brackets are bolted onto the spindle flange... Just go through the condition of the drums thoroughly before deciding. Also, unsure of your timeline and funds to make better suggestions.

Back to the carrier, I have a 4.56+ carrier that came from my front hp60. All 60s are reportedly the same. Get your BOM number off the axle so that I can double check part numbers, if you're interested.

My carrier is 35 spline too. Check what your spline count is on the stock one, I'm guessing 30 spline. If you were to want mine as-is, then last thing to confirm is if you can get 35 spline shaft through the spindle on your axle. $50 plus the ride.

 

I haven't taken the wheels off yet, I plan on doing that today to inspect brakes.


I tried taking the axle shaft out yesterday and ended up breaking a spline off my socket, I have a roommate that has an impact 6 point so I'll try that today. As for the BOM, there isn't one. I have searched the axle tubes up and down to only find surface rust. I plan on wire wheeling the entire passenger side tube to see if it got covered up with rust. Pics included if you want to see yourself.

 

There's a BOM on there somewhere. Who knows if you can still read it when you uncover the rust.

 

Well, I found some numbers, I had a hard time reading them so here's some picture...


None of them looked like they were in the correct order from what I found for Dana axle id. I did get to pull out the axle shaft today and counted 30 splines so I think I'll pass since a new carrier would be cheaper, thanks for the offer though. I am honestly getting ready so that I have to flip it, I can. The only thing I didn't get done today was get a look at the brakes. I forgot that there was a nut that holds the hub on, so that will have to wait till I can bring it into the shop. I did get some rough measurments from spring perch to spring perch and they were pretty close to exact. I am going to try to get some help tomorrow to get more exact measurements and get a final answer.

 

Just an update for anyone curious, I ordered gears, master install, and a grizzly locker to put in the differential. Should be here by the end of next week and installed shortly after. I did get to get around to measuring the spring perches and it is a little narrow by approximately 2''.