My Quest for 4x4

[Flightman91]

For those who would like the long story:
When my grandfather put my Bump together 8 years ago he wanted to get better fuel economy, but he also wanted the 4WD front suspension. So I ended up with a 4.10 Dana 44 on the front, a 3.73 Dana 60 in the back, and disassembled 4.10 Dana 60 in a shed for 8 years. Go to put it back together and I realize that the whole brake set up is...well its not in great shape. Now I'm going to out myself a little, I've always been a Chevy guy, my Dads a Chevy guy, and my neighbors a Chevy guy. So we were planning to fix the brakes and put the rear and back together. Thankfully one of my other neighbors is a Ford guy, and was over for a beer. He suggested why not just change the gears. So here's my question, what do I need to change the gears, primarily, is there a crush bearing?

For those who would like the short story:
What do I need to change the gears, primarily, is there a crush bearing?

[eggman918]

pinion preload is set with shims, this link is to the Dana 60 manual in PDF this has the info you need
http://www2.dana.com/pdf/5309-3.pdf

[Flightman91]

So after reading that and a few other items, I'm wondering, if I have 2 complete axles and I will be taking the gears from one and moving it to the other. Do I use the shims from one of those axles, or should I buy new shims or do I simply follow one of the several shims calculation charts I've found online?

[averagef250]

So after reading that and a few other items, I'm wondering, if I have 2 complete axles and I will be taking the gears from one and moving it to the other. Do I use the shims from one of those axles, or should I buy new shims or do I simply follow one of the several shims calculation charts I've found online?

The answer on shims is neither of the shim packs will be right and in addition you can never trust the job was done right the last time.

First you set pinion preload, then you set pinion depth, then backlash and carrier preload. The process isn't as straightforward as it sounds there, it requires a dial indicator, clamshell puller or setup bearings, but it is very simple once you understand it. Re-using old shims is a PITA, it's doable, but not really worth the hassle considering the cost of shim sets.

You don't use any charts to calculate shims. You need to understand the proper pinion and carrier preload requirements and know how to interpret the pattern the gears run. In order to interpret the gear pattern you have to tell how the gears were machined then select the proper pattern chart and use that to determine where shims need to go.

[Flightman91]

Could you recommend a good kit?

[Flightman91]

Still trying to get 4x4 in the truck. The 3.73 rear end has started leaking fluid out the drivers side axle, right into my brake drum. So I'm decided I might as well just refresh the axle with the right gears in it as it is already out of the truck.

So my question is, where are any seals/gaskets I should replace or anything else I should check before jacking up the truck? And are these semi or full float Dana 60's?