Can't Get Enough
Join Date: Sep 1999
Location: Cotopaxi, Colorado
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Re: Dana 60
I am in the process of cutting 2 front GM 60's now, for my 2 '83 CJ-7's. I picked up 1 complete 60 axle, less hubs and rotors, and another housing that only went out to the steering knuckles. I figured to chop them both now and worry about getting the rest of the stuff later.
I did a search on the POR board about lengths. I guess the stock GM 60 is about 69 inches wms to wms. An early Dodge 60 is about 67 inches wms to wms. The long side axle shaft on a Dodge is the same as the GM. Only the short side is different. Then I went to the local Driveline service of Colorado Springs to order my inner axles. I bought 2 short side shafts from a Dodge (35 spline). I cut the short side down to match, which ended up about 1 7/8 inches shorter. From here I measured the distance from the center bolt hole in the casting over to where I wanted my other purch, and marked the location. About 27 1/2 inches (the width of my CJ frame). Then I measured my short side out, and matched that length to the long side. This is where I chopped the long side. Now I only have to get the long side cut and re-splined. Before I welded my long side purch on I wanted to rotate the pinion up about 3-4 degrees. I ground down the cast in purch on the diff about 1/8 inch in the back and flattened it with a large flat file (using my angle guage) it worked out 4 degrees. Then I welded the long side purch on at the same angle. I should note, before I cut tho C ends off the tubes, I marked them for caster. When I re-installed them, I added the 4 degrees that I tapered the spring mounts to. I also tack-welded them so I could easily rotate them when on the alignment rack for caster.
This is the same method I used to shorten my SOA 44's from a Chevy that are in there now. I used a Wagoneer's short side shaft. I worked out perfect. The front 44 now is at 62 inches wide, which I think the 60 will also be at.
There is a big difference in prices. I dropped $400 for the 35 spline outers with the Warn 35 spline hubs. The short inner shafts cost about $90. ea. and $80 each for the long side shafts. I got the inner shafts at cost, about 1/2 off.
For the rear? I have never shortened a rear. Here is a link that may help.
<a target="_blank" href=http://www.bc4x4.com/tech/2000/highpiniond60rear/highpiniond60rear.cfm>http://www.bc4x4.com/tech/2000/highpiniond60rear/highpiniond60rear.cfm</a>