jeepsr4ever
10-24-2004, 03:21 PM
We are building a rear dana 60 for the shops grand cherokee. Here are the specs
1977 J20 dana 60 rear
30 spline full floater
4:10 gears
open carrier
shortened
We started with a housing and cut out 5 3/4"s on the long side of the tube. We ground large bevels and ground the rust away from the sides of the tubes to allow a nice penetrating weld. We used the triangle method and tach welded angle irons to the tube that has the pumpkin attached. This oriented the cut off end to the tube (really not a accurate way though) We bolted up the axle shaft and made sure their was enough concentricity in the tubing by using the same method on the axle shaft....basically bolting in in 3 places onto the hub. Next we tacked and Mig'ed the tubes together where we could without welding the angles. Next we cut the angle iron off and finished the weld. Keep in mind that on a full floater the tube is the seal and you will need to penetrate this tube well. A mig setting of 208 on the voltage meter and 238 on the wire speed on a Miller 251 ....which we also used mild steel wire. The tube was welded together here just 15 mns ago and the penetrating was great. Pics are coming very soon as I just need to get them off my camera but this is a great way to shrten a full floater. The best part is that we can now take the short side axle from a junk or junkyard dana 60 from a J20 truck and it will fit our new shortened side.
I do have a 35 spline carrier laying around but I am not sure if I want to use it in a 60 or a 60-2 :-|
I will get back with pics soon
1977 J20 dana 60 rear
30 spline full floater
4:10 gears
open carrier
shortened
We started with a housing and cut out 5 3/4"s on the long side of the tube. We ground large bevels and ground the rust away from the sides of the tubes to allow a nice penetrating weld. We used the triangle method and tach welded angle irons to the tube that has the pumpkin attached. This oriented the cut off end to the tube (really not a accurate way though) We bolted up the axle shaft and made sure their was enough concentricity in the tubing by using the same method on the axle shaft....basically bolting in in 3 places onto the hub. Next we tacked and Mig'ed the tubes together where we could without welding the angles. Next we cut the angle iron off and finished the weld. Keep in mind that on a full floater the tube is the seal and you will need to penetrate this tube well. A mig setting of 208 on the voltage meter and 238 on the wire speed on a Miller 251 ....which we also used mild steel wire. The tube was welded together here just 15 mns ago and the penetrating was great. Pics are coming very soon as I just need to get them off my camera but this is a great way to shrten a full floater. The best part is that we can now take the short side axle from a junk or junkyard dana 60 from a J20 truck and it will fit our new shortened side.
I do have a 35 spline carrier laying around but I am not sure if I want to use it in a 60 or a 60-2 :-|
I will get back with pics soon