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Old 05-19-2007, 02:34 PM
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Nearly Stock YJ Rebuild

I figured I better start a new thread instead to pirating someone else's upgrade thread, sorry.

I am reworking the front suspension on my YJ from SOA to Coilovers and links. At the same time I started to have trouble with the front end of my tow rig a 96 F-250 with the IFS front axle. As I had a ball joint D60 in the jeep right now that will bolt into the truck I decided to get a king pin D60 to install in the YJ and fix the truck with the old one.
At this point I just completed (with Jack's and Joe's help) disassembling the king pin 60 and cleaning it up. next week we will start rebuilding it. The nest step is to take both the truck and YJ to the shop and swap the ball joint 60 into the truck. Then the fun begins.

New King pin 60 disassembled



Cleaned up and about ready for paint



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Old 05-19-2007, 07:40 PM   #2
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Did you replace your kingpins? If so, did you have any trouble getting them out??

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Old 05-19-2007, 08:57 PM
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No they have very little wear on them. If I did replace them I would expect a lot of trouble as they are a 7/8" hex and torqued at 600#. Good luck
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Old 05-19-2007, 09:04 PM   #4
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You are lucky. I wish I had that kind of luck. I had to tear into mine cause they were pitted pretty bad. This is the easy way to get the kingpins out.



popped it right out of there.



Then you need a big allen wrench to put it back in.

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Old 05-19-2007, 09:15 PM
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I m glad I missed out on that adventure.
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Old 05-20-2007, 03:01 AM   #6
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Andy, that's pretty much exactly how we talked about doing that should we ever have to. I hope we never have to.
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Old 05-20-2007, 09:28 AM   #7
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for your sake I hope so too. I lifted my axle into the bench vice in order to hold it still while I torqued it down. That big allen wrench only cost me 15 bucks though so no big loss. Now I know my front axle is in excellent condition and I can go from there.
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Old 05-22-2007, 09:24 PM
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Well we painted everything today. It looks a lot better





Some new parts should be in this week to put everything back together.
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Old 05-22-2007, 09:45 PM   #9
 
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Man that looks good. So now you will be running "Dual Dana 30s" In your Nearly Stock YJ........ Looking forward to the final project Jim, It will be kick a$$...Then we can Re-Tub my TJ.....


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Old 05-22-2007, 10:38 PM   #10
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Dual front Dana 30's is the only way to go.

Holy looks like a brand new axle batman. Looks smokin Jim, can't wait to start gettin to work on that nearly stock axle build.

Oh, and damn Joe you had to bring up that re-tub again.
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Old 05-23-2007, 05:39 PM
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I just got off the phone with a company that is proto typing a new front D60 truss. It will have the drivers side upper control arm mount built in and a track bar mount set up for high steer. They do some nice work. As soon as everything is set I will put out the company name.
This is a pic of the truss they make for a HP44.
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Old 05-23-2007, 11:19 PM   #12
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Hackle, that looks pretty good boss. Be nice if it works out. Will make that front end bullet proof.
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Old 05-24-2007, 11:54 PM
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Made some progress today as we got the king pin rebuild kits delivered and installed.
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Old 05-28-2007, 05:08 PM
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Thanks to Joe @ Absolute Offroad we installed the gears and OX locker today. After a long look at the rusty stock inner shafts we decided to order new Alloy front inners to match my Alloy 35 spline outers and Bobby Long U-joints. I hope to have the new truss and high steer arms soon so we can complete the axle and start install.







Joe spent a lot of time helping me learn to set up the gears today and as I will be setting up the Ball joint 60 for my truck I may actualy get the feel for gears yet Thanks again Joe.
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Old 05-28-2007, 06:31 PM   #15
 
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Quote:
Originally Posted by Hackle View Post
Thanks to Joe @ Absolute Offroad we installed the gears and OX locker today. After a long look at the rusty stock inner shafts we decided to order new Alloy front inners to match my Alloy 35 spline outers and Bobby Long U-joints. I hope to have the new truss and high steer arms soon so we can complete the axle and start install.







Joe spent a lot of time helping me learn to set up the gears today and as I will be setting up the Ball joint 60 for my truck I may actualy get the feel for gears yet Thanks again Joe.

You are always welcome, Jim. Oh my freaking back!!!! I honestly believe that the OX locker and a set of D60 gears weigh about 110+ LBS!!! At least there are good pills in the medicine cabinet....... When you took those pics, the shop looks like a bomb went off in there..... Its really not that messy....... Oh...And before anyone asks, the green paint marks are how I mark and check stuff on final assembly. Lets me remember that its DONE....Man, gettin old sucks.


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Old 05-28-2007, 11:55 PM   #16
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Nice work fella's. Sorry I missed out today. Golf course was callin me this morning. Only sucky thing was I came in third so no money for me.

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