Dana 60 also has shims for the pinion not a crush sleeve like 9.25. The crush sleeve getting crushed too much will cause slop in the pinion and destroy the axle. That is what happened to mine and has happened to many others. The crush sleeve will crush itself more if the truck is under a lot of throttle and load. So it is not just a setup mistake.

 

You would have to setup the axle again then. If you just replace the spiders it is much cheaper and simpler.

 

just replace the top and bottom spiders and the side gears on the axle. check pinion shaft in the carrier case for smoothness. if its nicked up any, either grind it out smooth or replace it too.

it'll only cost you about $100 or less and you can be done in 15 minutes. as said, if you try to pull the carrier, its a big job and requires a setup which will cost you a lot of money to have done.

its an easy repair - just follow the steps in the haynes manual (pg 8-12) or 01 service manual to -
locate and remove pinion shaft lock bolt.
remove pinion shaft.
remove c-clips.
slide rear axles out a tad.
replace side gears.
replace top and bottom spiders and shims.
reinstall pinion shaft.
push axles back in and reinstall c-clips somewhere in here...
done...

 

its your truck and all and you can do whatever you want - but you might have found the line of abuse that you should not cross. LOL.

 

Well i realized my axle wasnt "open" its a Trac-lock. The local axle shop had a spider kit on hand but beings mine has clutches and all that fun stuff i couldnt use them. i figured maybe i could use the upper and lower out of the kit but they are a different teeth count than what i had. We went in his inventory and found tons of carriers and stuff but no track-locks. He however has plenty of open carriers and is going to sell me a complete open carrier. So im going to be doing one wheel wonders from here on out untill i figure out what else to do. looking to get this thing running asap since its my dd. Just gotta get new carrier bearings which hes pressing onto the carrier tomorrow and swap the ring and pull the axles then set the backlash. he has lock right lockers available, but from what hes saying they are junk for bigger trucks and wear out quick with the bigger tires. im spending about 150 bucks to get this going again and a detroit would cost $500+ and a lockright locker is $270 so im going cheap. guess ill end up rebuilding the track-lock sometime and keep it available.

 

Yea i tend to destroy my vehicles pretty quick. im a jeep guy, owned 2 still have one. no broken axles before but went through about 7 drive shafts with my cj and the 40" gumbo's. what may have caused this was the bouncy rear springs and the long gravel road with potholes that made the rear tires bounce off the ground multiple times. was a fun ride though :P

 

Don't settle for an open carrier. You will only get to pay to upgrade again later. Spend the money now, and then you won't be paying for the same job twice.

Rebuild your trac-lock. You won't be happy otherwise.

 

oops, i didn't even consider that you had an LSD. its a booger to compress the clutches and reinstall. there's some good pics and info in a thread in here somewhere.

don't even consider a lockright with your big 35" tires. it won't hold up.

are you getting a rear end repair and setup for $150 - if so that's a unusually good price. if you could stand the downtime, just order spiders and a posi rebuild kit.

 

Yes sir. I just went and picked up the carrier along with new bearings pressed on it and a gallon of fluid. The spiders are clean and look new. The guy also gave me a couple packs of locktight and stuff to mark the ring when im setting the backlash. cost me $140 bucks as i assumed. It is a pretty good price. He charged me 75 bucks for the carrier alone. I know i am going to be upset when im only turning one tire but ive gone a week without my dd and miss my truck. Will probably keep the lsd and rebuild it and keep as a spare. Now the problem lies with finding the tool to adjust backlash and getting a car jack.