91 Exploder Dana 60 Install

[KF5ZXT]

Yeah, same here.

[KF5ZXT]

Order another pair of forged Ballistic Rod ends, an inner frame bracket and an 8 lug spare tire mounting plate. Got the additional rod ends incase it looks like a 4 link might work better for me than the three link, and if not, nice to have spares.

[KF5ZXT]

Anyone happen to have an extra 4.0 OHV power steering pump bracket laying around?

[Justin Klare]

I just might

[KF5ZXT]

Sweeeeet.

[KF5ZXT]

New flat bottom heat treated lower king pins are in.

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[Justin Klare]

I looked and I do have a spare. Want me to bring it up this weekend?

[KF5ZXT]

If it's not too much trouble .


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[KF5ZXT]

Ordered the Hydro kit. And also these:





The following manufactures have all made parts that are going in to this swap so far:

Reid Racing
Artec Industries
Ruff Stuff Industries
Ballistic Fabrication
Longfield Super Axles
Warn
Yukon
Sway-Away
USA 6x6
PSC Motorsports
Detroit
USA Gear
East Coast Jeep Supply
Crane High Clearance

[Justin Klare]

Bad ass!!!

[KF5ZXT]

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[TxPlates]

Damn you and your shiny new toys.

[TexasArmadillo]

I don't see any breweries on ur manufactures list.

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[KF5ZXT]

Lol, good point. I knew I forgot something.

[BigTim55]

All sorts of shiny goodness

A 2WD in a 4WD world

[Justin Klare]

Saw this kit in person. It was very hard not to load it up in my vehicle as well

[KF5ZXT]

Wow, the power steering pump reservoir is a bit larger than I had anticipated.

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[Kris Guilbeaux]

So when is it going to TAG for install?

[KF5ZXT]

Good question. Soonish?

[Kris Guilbeaux]

Oh I figured you at least had it scheduled with them

[KF5ZXT]

No, I need to do that soon. Trying to nail down Parker's schedule since he wanted to attend as well.

Also, I'd like to finish up a couple things before I take mine up there, such as mount the wheels, carve out the power steering pump bracket that Justin brought me to fit the new power steering pump in, and change out the knuckles/brakes on the front 60.

[TxPlates]

When you plan on getting what you want and we can plan from there.

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[KF5ZXT]

I'm also thinking that while I have the front 60 apart, I'm going to convert from 1/2-20 wheel lug studs to 9/16-18 wheel lug studs, to match the rear. I can either drill out/attempt to press in Dorman 610-278 wheel studs into the hubs that I have now, or switch over to a late 80's F250 HD Dana 50 hub, which already uses that same wheel stud. Everything else from a dana 60 is supposed to line up on the dana 50 hub.

Or, I may not need to drill out the current hub if there is enough tolerance. According to Dorman, the hole should be .017 to .027 smaller than the size of the knurl. I'll have to take one of my hubs apart and measure how big the stud hole is with my digital caliper and see if it's within tolerance. The 610-278's are .620 at the knurl, so I'll be hoping for a range inbetween .603 and .593. In comparison, the 610-279's that are stock on the 79 Ford D60 are .602 at the knurl, which means it's hole should be .585 to .575 Hmmm, looking at those numbers, it's likely that I'll have to drill the hub out. A 39/64" drill bit is: .609. A 19/32" is .593. So the 39/64" would probably be the best bet.

As far as mounting the wheels goes - I have to either drill out the rectangular valve stem hole to accept a round valve stem, or fork over about $200 to get 4 of the original versions that are used on the wheels. RIght now I'm thinking I'll drill them out. Just need to determine the correct size.

[TxPlates]

What's it gonna cost if you mess up the size. I'd compare that to the 200 and make the decision from there.

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[KF5ZXT]

Yep, that's basically why I haven't done it yet, lol.