I already did the track bar about a year and half ago, but it's time--- Probably way beyond time, for ball joints, tie rods. I got almost 1/2 inch slop up and down in the outer tierods. yep.. I get the goody out of stuff..

So, looking at components from moog. outer tie rods (2) the inner tie rod to pitman, and the connecting bar from that TR to the main drag link. Might as well throw in new connector sleeves too.

Then might as well do the ball joints too, Moog again. I'm only going with the standard non offset type. anyone know why they offer 'adjustable' camber +/- 1 1/2 degree?

...the offset do have an advantage I suppose, the uppers are greasable, whereas the normal ones are not.. just the lowers. Was there a axle problem that necessitated these type of joints?

Looks like about 416 bucks from RA.. I get to unwrap my new ball joint press kit!!

Just for giggles, anyone want to wager how much my economy will improve when the front tires are running straight again?? Last set was buzzed off in about 10k miles...

lmao...  I   just couldn't imagine you  dragging the whole  front axle  over to the shop press!! 

Rancherman you have a PM

I think I'm missing  a  bushing that goes into the end of  the   axle..  and  the smaller  end of the  intermediate goes into.         it'd  support the   axle,  and allow it to flex  when  the steering  turns.     It's probably plastic,  and  long  gone.   Back to searching parts books..

Dang!   It really sucks when your fully committed to a project with parts scattered everywhere, only to realize you don't have everything you need to put her back together!

Update!   FINALLY  found  the  correct  parts... man!  what a  struggle.      Dealer  was clueless  on  how to even   find   which  axle  I   KNEW I HAD!!       I even  had  the   build tag   in my hand!  (Dana  bill of  parts)...

Down the road!    next stop,   a  transmissions shop  I've trusted  for years...  HE needed  the  VIN  number.      ugggggg  

 

Back home  behind my trusty laptop!      

 http://www.cumminsforum.com/forum/attachments/98-5-02-powertrain/328490d1421691799-dana-60-rebuild-question-99-01-spicer-axles-60-front-bom.pdf

http://www.cumminsforum.com/forum/attachments/98-5-02-powertrain/328498d1421691799-dana-60-rebuild-question-99-01-spicer-axles-60-front-exploded-view.pdf

 

These  downloads  will  give  the   98.5- 2002    dana  axle   exploded view,  parts  numbers    (all   Dana/spicer #'s)  for ALL years,      and  plugging THOSE  numbers  into a  search   gave me  exactly  what I need!   It  was  a  sneaky and  tedious   way to come up with   actual part numbers,  but  dang it!  I WON!!  

 

 

Innermost  axle  disconnect  shaft,     Bushing,  and    outer  shaft...  yes,  that  was  buggered too.     My  stub shaft is  fine.  

  Yesterday,   I would've been  forced  to  buy  a complete  outer axle,  ~375 bucks,   had no idea  if  the inner output shaft  was even available,   and  no clue about  some sort of  bushing!

Tonight,   I'm   looking at    165  for the inner shaft,  175 for the outer shaft,   5 bucks  for the  bushing...      345  plus shipping.     Yea!      

I  believe  I   justified  this month's    internet  bill!

Edited January 20, 201510 yr by rancherman

Update! FINALLY found the correct parts... man! what a struggle. Dealer was clueless on how to even find which axle I KNEW I HAD!! I even had the build tag in my hand! (Dana bill of parts)...

Down the road! next stop, a transmissions shop I've trusted for years... HE needed the VIN number. ugggggg

Back home behind my trusty laptop!

http://www.cumminsforum.com/forum/attachments/98-5-02-powertrain/328490d1421691799-dana-60-rebuild-question-99-01-spicer-axles-60-front-bom.pdf

http://www.cumminsforum.com/forum/attachments/98-5-02-powertrain/328498d1421691799-dana-60-rebuild-question-99-01-spicer-axles-60-front-exploded-view.pdf

These downloads will give the 98.5- 2002 dana axle exploded view, parts numbers (all Dana/spicer #'s) for ALL years, and plugging THOSE numbers into a search gave me exactly what I need! It was a sneaky and tedious way to come up with actual part numbers, but dang it! I WON!!

Innermost axle disconnect shaft, Bushing, and outer shaft... yes, that was buggered too. My stub shaft is fine.

Yesterday, I would've been forced to buy a complete outer axle, ~375 bucks, had no idea if the inner output shaft was even available, and no clue about some sort of bushing!

Tonight, I'm looking at 165 for the inner shaft, 175 for the outer shaft, 5 bucks for the bushing... 345 plus shipping. Yea!

I believe I justified this month's internet bill!

Seems that these days no one cares too much about going extra few feet to help another out, very few. Thanks for search and links, I might be doing this soon as my ball joints are on the way out. I think reason your shaft was wore out is maybe bad ball joints, axle would be misaligned and puts stress on where collar is. Just guessing.

Very possible!

After reading  through  a lot of   sites  on this  CAD..   It seems  the little plastic  bushing  that    inter connects  the  2  shafts  is  a very  often  overlooked  and  high wear   part. 

It's  about  5  bucks,  and  when it's  pounded out,   the  shafts  are no longer  aligned  radially...    and   begin to  eat each other  up  too... 

It'd  be  good  to replace each time  the shaft is  removed  for   any reason at all.

 

 

FIL   had  this  truck   before me,  and if my memory serves,   had  a  wheel bearing replaced  years ago..   It's  very very possible   those  guys   didn't  verify  if  that little  bushing  was even in there. 

 

No matter,     it's all good now!       I'm awaiting  the final piece to arrive,   I might as well replace  the  inner plastic  bearing  (inboard of the CAD opening) .  

OMG.    

talk about   trying to find the proverbial   needle in a  haystack!

 

This almost  could be a  'sticky'! 

 

using   'normal'  search  in  a  mopar  parts   book is  worthless as a fart in a whirlwind.

 

BACK TO  DANA/SPICER   AGAIN

 

Go to this  site:    http://www2.dana.com/expertforms/depart.aspx?part=CHRY_60/248_FRO(VAR)

 

Then this will  give you a list of   every  Dana 60  ever built.   snag the  BOM  tag off the  differential cover  (usually a   61XXXX   include  dashes and  suffixes too)  and  click on your number from this list.

This will bring up  the  parts list  to your  particular axle,   and  using this   link;  http://www.cumminsforum.com/forum/attachments/98-5-02-  powertrain/328498d1421691799-dana-60-rebuild-question-99-01-spicer-axles-60-front-exploded-view.pdf   will get you a  generic  exploded view.    

See the part you need?   take the  item #,  and  look it  up  in the  list.   viola!  

 

If  needing    parts  for  a different model,  say  33, 44,70 or  80...  just go to   http://www2.dana.com/expertforms/demenu.aspx?prod=AXL    Type in your  BOM,   and it  will take you to  where  we started  above^^^

 

This  is  certainly  a  long way around the horn...  but   compared to finding parts  for these axles  in  any  Mopar parts  searches..   I'll say this is  the most accurate.

 

example,    searching for  the   axle  bushing today,   I went to    numerous   mopar parts online.      went through the hoops,  and  came up with  a  bushing  that will  FIT   any  dana  (1500, 2500,3500)    umm,  no.    the  44 is  most  definitely  smaller  shaft,  and  the bushing will also be smaller..     I went through this issue  last week  with the output intermediate shaft as well!.    They  said  the   output  would fit  any 1500,2500,3500 (made  in 2000-2002 that is)    wrong.  

 

So,  I came up with  a  Dana spicer  number of     49488   for the bushing reqd.    16 bucks. 

Have you ever checked Quad 4x4 out? I honestly have no idea if they would have everything you've needed up to this point, but they do have a pretty solid collection of Dana/Spicer stuff. I was going to mention it your last go round, but it seemed like you found everything you needed at the time.

http://quad4x4.com/#Dodge

yep.    They have a nice   breakdown  of  common  parts needed  for our axles,   according to  year and model. 

Unfortunately,   they no longer  sold the intermediate shaft  I needed last week!       which  got me   hunting  elsewhere.

 

Right now,  they have the bushing I need,  but dang!  he wants  19 bucks  to send it!   it  weighs   .06 lbs!  C'mon!   

When something comes up like that and shipping seems way out of whack I will usually call and talk to someone. 9 times out of 10 they will lower the charges to a much more reasonable rate, if not I tell them thanks but NO THANKS!

update..

Both sides  are  now sporting new  ball joints.  knuckles  are still on the ground...   awaiting   delivery of  the   plastic  bushing.     Then   It should be  a  pretty  easy  re-assemble.

Where did you end up getting the plastic bushing? Sorry if I missed it

libertytruckandauto.com 

 

bushing  was   about  18 bucks..  and  they were  about 2 dollars  less to ship.   $ 34 total.