One Ton Axle Build Thread

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[Twisty]

It will be a slow build up, but I might as well start now.  1978 14 bolt full floater from a K20 pickup, and a 1979 high pinion D60 from a F250 Snofighter pickup.  14 bolt is 3.73 ratio, and and the D60 is 3.55 ratio.  Both will get 5.13s or 5.38s, and both will be locked in some way or another.  Before these axles are put under the MJ, it will need some reinforcing.  I'm going to plate the uni-frame with some 3x3 angle iron, and tie some rock rails into them.  My hope is to create an exocage that will tie into a front bumper, rear bumper, rock rails and a few other points that I am not yet sure of.  I think that with the MJ's fully boxed rear frame and some support up front that it can handle one tons.

I originaly decided to get the 14 bolt this fall when I had the oppritunity to purchase a pair of D60s from a 1978 F350.  But it turned out that the front was bent, and the whole thing was useless.  So I had a 14 bolt sitting here.  I contemplated selling it until I located a D60 on craigslist. 

When I arrived home with the axle.




Then I took the drivers side appart so I could rebuild the kingpins, and clean up/paint the parts.
Here is the knuckle.


Today was an exciting day because I was able to remove the kinpins!




Those things were in there with 500ft/lbs of torque and were fun to break free.  You can see my little "tool" that I made out of a bolt and a nut that I tried to use to extract the kingpin...but it failed.  I wound up using a pipe wrench with a 6' pipe on the end.  The only part I over looked was getting the stupid NEW kingpin back into the C and torqued correctly.  Oh well.

I will be ordering 2 of these tonight so I can re-assemble the 60 and get it ready for future modifications.
http://www.4wdfactory.biz/osc2.2/product_info.php?products_id=52


As I progress with this project I will add pictures so anyone who wants to see them, can.  As always, suggestions/comments/constructive criticism are welcome

[rich]

just curious but were the king pins worn out ?
and how are you going to re-torque them to the correct setting ? i thought i rear some where that the torque setting was 600 ft-lbs

[Twisty]

just curious but were the king pins worn out ?
and how are you going to re-torque them to the correct setting ? i thought i rear some where that the torque setting was 600 ft-lbs

They were pitted a little, and I was bored so I figured I'd switch them out.  I'd rather do it now then have to not go wheeling because they were sloppy.  It was fun though.

As for re-torquing them, it seems that many people on Pirate use large chisels from Home Depot that are made out of hardened 7/8 stock.  Cut off the chisel...and you're left with 7/8 stock!  I'll see about getting that, and using a 3/4" drive with a pipe on the end.  My uncle has lots of tools at work, and he said that he'd keep an eye out for me. 

EDIT: Rich, would you have swapped them out?  Are you planning to do so with your 60?

[rich]

mine seemed nice and tight. i can't belive how much it is costing me to swap over to 1 ton stuff, so if it aint broke im not messing with it. if there was no play in them i would have left them be

[Twisty]

So Rich got me thinking about my problem of getting the kingpins back in.  I went to the hardware store looking for numerous things that I could use to make a 7/8 hexagonal tool that I could remove reinstall the kingpin with.  I looked at chisels, crow bars, bolts, and solid stock that I could cut down.  Then it hit me!  I had an old D35 shaft sitting in the woodshed, so I got to work.

I started by cutting the axle down to size.  I relocated from this spot after I cut a nice slit in my finger with the cut off wheel .


I needed the correct size, so I tack welded a 7/8 nut head to the end of the axle to act as a guide that I could cut along.


Started to grind the hexagon.


End result!




You can kind of see, but the kingpin bottoms out on the hex with about .5mm left between the lip of the kinpin and the edge of the shaft.



My only concern is that the hex wont be strong enough to take the torque of reinstallation.  I plan to just use a pipe wrench on the shaft with a large breaker bar on the end.  Perhaps some red loctite will ensure that it will stay put if I dont get it close to required torque (but I'm not too worried about that).

Oh, and the kingpin rebuild kits were ordered last night, and they should be here tomorrow!

[Switch]

hahaha now that is a great use for a dana 35!

[Twisty]

And you might have seen how I used the pinion gear from that same D35, on my transfer case shift lever

[Twisty]

Well the kingpin rebuild kits came!  I placed the order Monday night from Doug at www.extremeaxlesales.com.  I saw his vendor thread on Pirate for $50 per kit shipped, and I jumped on it.  The other places I looked wanted $49 per kit and ~$15 for shipping! 





I'm in the process of degreasing the whole axle, and will paint it soon.

[Krome]

good thing you didnt get a ford axle with balljoints


man i hate ford balljoints on 60s!!

[cj7fan]

Cool thread Twisty..!  I am glad to see more stuff in the tech section with pictures   I don't know anything about these huge axles (except everyone wants them and they are HEAVY) so I am interested to learn all I can.

When you finally get these built and installed are you going to keep your stock engine or are you going to need an upgrade?

Keep up the good work and btw, that trick you showed me on the t-case lever for the XJ (pushing it forward) stopped that noise when sitting at idle.....thanks!!!

Kent

[MMagnumPI9]

Well the kingpin rebuild kits came!  I placed the order Monday night from Doug at www.extremeaxlesales.com.  I saw his vendor thread on Pirate for $50 per kit shipped, and I jumped on it.  The other places I looked wanted $49 per kit and ~$15 for shipping! 





I'm in the process of degreasing the whole axle, and will paint it soon.

I have dealt with doug before with good results.

[jps4jeep]

Good Tech! 



Question

Why choose a bolt? Would it have been easier to use a 1 1/4" 4 sided nut and lop off the corners with a grinding wheel or cuttoff wheel, clean it up the correct proportions and weld the center of the nut onto the shaft?  Just wondering though.


Still, Looking Great! Keep the tech coming, Lovin it!

[jps4jeep]

If you want, I have some degreaser at work, need to wear a face shield, respirator, gloves and chem apron, but it will clean your axle up awesome!

[Twisty]

If you want, I have some degreaser at work, need to wear a face shield, respirator, gloves and chem apron, but it will clean your axle up awesome!

I'm going to try the old method of a screw driver, and wire brush.  It might take a while..but I dont mind.  If I start to go insane, I will PM you.  Thanks for the offer!

I used the bolt because I had one laying around, and didnt want to make the trip to the hardware store.  But why would I use a 4 sided nut?  Can you explain?

EDIT: I think I know what you mean.  I didnt leave the nut welded there.  I just used it as a guide, and chopped it off at the end. 

[Twisty]

Cool thread Twisty..!  I am glad to see more stuff in the tech section with pictures   I don't know anything about these huge axles (except everyone wants them and they are HEAVY) so I am interested to learn all I can.

When you finally get these built and installed are you going to keep your stock engine or are you going to need an upgrade?

Keep up the good work and btw, that trick you showed me on the t-case lever for the XJ (pushing it forward) stopped that noise when sitting at idle.....thanks!!!

Kent

I'm going to keep the I6.  I like it, and it is simple to work on.  A V8 is too advanced for me at this point. 

I'll try to keep the pics coming.  Sometimes I get carried away with cleaning/grinding and I forget to take pics.  Oh, and I'm glad the shifter handle trick works...my XJ does that too.