Dana 60 35 Spline Upgrade Kit
The Dana 60 front axle is very stout in stock form, but if it has a weak
link it is generally considered to be the outer stub shaft which is approximately the
same size as a Dana 44 stub shaft. By upgrading the outer stub shaft to a
35 spline unit (originally
for a Dana
70) it will now match the stock inner shafts and have 1.5" x 35 spline
throughout. In addition to upgrading the stub shafts the old 30 spline
locking hubs will also need to be upgraded to 35 spline units. Fortunately
Warn makes a few different 35 spline hubs that were originally intended
for rear D60 and 9" (Ford) full float applications that will also
work on a front Dana 60 axle with 35 spline stub shafts.
When we started shopping around for the parts we needed for this
upgrade we found them to be pretty expensive especially if you wanted to
change out the u-joints to Spicer's new forged units which we would recommend.
Fortunately there is a company called the 4wd Factory in Texas that has
put together a 35 spline upgrade kit that even includes the new Spicer
forged u-joints for an awesome price. With a very low price and the great service
they offer it was a no-brainer to go with them, it was also nice to get
all the parts from one source.
2 - Dana Spicer 35 spline stub shafts (382871).
2 - Dana Spicer Forged U-Joints (SPL55-4X).
2 - Warn Premium 35 spline locking hubs (62672).
Optional - Upgrade to Warn drive flanges
for an additional $25.00 (39346).
(bottom) compared to cast 5-332X
||35 spline stub
shaft pictured next to the stock 30 spline version
||35 spline Warn
Premium locking hubs
Remove the old shafts by removing the brake caliper,
hub and rotor assembly, spindle and backing plate. A six prong hub socket
is needed to loosen the hub nut or you can tap it loose sometimes with
just a screwdriver.
hub and rotor assembly
|Remove spindle and backing
To install a new 35 spline stub shaft the old u-joint
will have to be removed, this is a great project to utilize your vice if
you have one. Locate 4 small c-clips on the inside of the axle shaft, to
remove them, tap the end of them with a screwdriver until they come out
enough to pry out, all four need to be removed.
Place the axle shaft assembly in the vice with the
short side yokes clamped down and the long side yoke hanging freely. Now
comes the fun part, with a large hammer hit the long side yoke right
behind the cap, repeat as necessary until the cap starts to come up out of
the yoke, don't be afraid to really get after it especially if the
u-joints have not been replaced for a while. Once the cap is out far
enough you can pull it out the rest of the way with a pliers, flip the
axle assembly over and repeat the process on the opposite side.
||Hammer the yoke
until cap starts to come up
After the caps have been removed from the long side
shaft, separate the long and short side, if the old u-joint is in good
shape you might want to keep it in the short side shaft and use both as a
trail spare, if you do this you will also need to keep the old 30-spline
hub. If you want to remove the old u-joint from the short side shaft that
you will no longer use, simply place the u-joint on top of the vice and
bang away until it pops out.
Remove the u-joint caps from the new forged units and
position the joint inside the axle yoke, at this point you can install the
caps into the yokes from the outside, then simply place the yoke in the
vice and slowly tighten until the caps slide inward and you get to the
grove where the c-clips go in, then tap in the clips, repeat the process
for the other caps. After the u-joint is installed is a good time to
install the grease zerk and pump a little fresh grease into the new
u-joints. Also, don't forget to remove the slinger (stone shield) from the
old stub and put it on the new stub shaft.
|Position the joint inside the axle
|| slowly tighten until the caps slide inward
||Ready to install
Now it's time to install the axle shafts back into the
axle, insert the axle shaft assembly, install the backing plate, then
carefully install the spindle over the new shaft. After the spindle nuts
are torqued down the hub/rotor assembly gets installed, using a 6 prong
hub socket, tighten the adjusting nut to 50 ft lbs and then back it off 90
degrees. While continuing to rotate the wheel, tighten the adjusting nut
to 35 ft lbs and then back it off 3/8 of a turn. Install the lock washer
and outer locknut, then tighten the outer locknut to 65ft lbs. Bend one
ear of the lock washer over the inner nut and approximately 60 degrees
over the outer nut.
and backing plate
hub/rotor, lockouts, brakes etc.
The body of the hub is installed along with the large
and small snap rings then the large o-ring is inserted in the new hub dial
and finally installed. Six small screws are installed with o-rings which
help keep water out of the new hub.
|35 spline stub
shaft pictured next to the stock 30 spline version
That's it, your ready to wheel with additional
confidence knowing that your Dana 60 now has 35 spline 1-1/2" axle
shafts throughout. You run a Dana 60 because you needed the strength,
don't let the weak 30 spline stub shafts ruin your fun, call 4WD Factory
and upgrade today. - Steve Fox CK5