How to rebuild dana 60 front? - Cars & Trucks

Fully rebuild, or partial rebuild? Pinion, ring, spider gears, pumpkin, bearings? Rebuilding it FULLY and PROPERLY is a big story, one too big to relate here, and it takes quite a lot of special tooling (differential spreader, dial indicators, etc). Please don't attempt this unless you have a well equipped shop.

If you just need to replace the spider gears, that's easy. Drain the oil, remove the cover, rotate the pumpkin until you can unbolt the crosspin. Push/pull the crosspin out, rotate the spider gears until they come out. Remove the side gears. Remove all four thrust washers.

Replace all four thrust washers, then the new side gears, then mesh the new spider gears with the side gears & rotate them into place. If the crosspin hole won't line up, rotate one axle shaft until it does. Install the new crosspin and bolt it in. Replace the cover gasket and cover, refill.

Going further requires a LOT more work, but you'll need to remove the spider & side gears first anyway. If you're replacing bearings or the pumpkin or the ring & pinion, you'll need a bunch of new shims to work with until you can get the ring-pinion clearance exactly right. You'll also need a differential spreader to get enough space to remove/install the pumpkin with its bearings in place. If you're replacing the pinion gear, you'll need to take some painfully exact measurements or you'll NEVER get the ring/pinion clearances correct.