Front axle D60 seal replacement
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Elder User
Joined: Oct 2004
Posts: 782
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From: Olympia, WA
Front axle D60 seal replacement
I noticed last night that my front axle is leaking. Nice new royal purple oil dripping, what a waste. I just changed it a few hundred miles ago. I'm not talking about the cover, it's leaking out the end of the axle tube. I didn't find much for threads on this subject, most guys seem to take it somewhere for seal replacement. I did read that the front diff has to come out to replace the seals. Anyone done this job themselves?
Post Fiend
Joined: Oct 2003
Posts: 5,903
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From: MICHIGAN
Yep, the gears need to come out of the housing. Big job but do-able if you have the time and tools. The seals are pressed in from the inside gear case.
It seems that every time I change the fluid in a front d60 it leaks a little out of the tubes and then stops.
Try parking the truck with one tire higher over night and then the other side. Maybe it will just go away.
It seems that every time I change the fluid in a front d60 it leaks a little out of the tubes and then stops.
Try parking the truck with one tire higher over night and then the other side. Maybe it will just go away.
Postmaster
Joined: Feb 2004
Posts: 3,266
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From: Levittown
Yep, the gears need to come out of the housing. Big job but do-able if you have the time and tools. The seals are pressed in from the inside gear case.
It seems that every time I change the fluid in a front d60 it leaks a little out of the tubes and then stops.
Try parking the truck with one tire higher over night and then the other side. Maybe it will just go away.
It seems that every time I change the fluid in a front d60 it leaks a little out of the tubes and then stops.
Try parking the truck with one tire higher over night and then the other side. Maybe it will just go away.
You have to remove the hub/spindle to remove the axles to get the diff out.
As stated seals are behind the shims on the inside axle tubes.
Bill
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Elder User
Joined: Oct 2004
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From: Olympia, WA
What will I need for tools? I've seen the spreader type seal press, I could buy or make one of those. Gears scare me though. Is it safe to pull the diff and keep track of the shims and reassemble, or is this really a job for somebody that knows how to set up the gears? I'm not afraid to try it, but I want it done right. If that means I need to buy a few tools, that's ok. If I'm over my head though, I may have to take it to a gear shop. If I tear into this, what else should I replace while I'm in there?
Post Fiend
Joined: Oct 2003
Posts: 5,903
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From: MICHIGAN
No spreader needed...just basic hand tools. You will leave the pinion gear in the housing so no measurements are needed, Just keep track of everything as it comes apart. I would get all new seals for the 4x4. If the ujoints on the axles are old or worn now is the time to replace them too. I replaced mine with grease fitting types. Same goes for the ball joints....if they are old or worn....replace. You are going very deep into the front axle so now is the time to do it all and do it right.
TRhe hard part is getting the spindles off the knuckles. They are usually rusted together pretty good. I knock out all the studs first and then remove the spindles....you'll see.
You may need to fab up a chunk of pipe to push in the seals. I hammer them in through the axle tube(s) Or use threaded rod to push them both in at the same time. The seals are delicate so take your time.
TRhe hard part is getting the spindles off the knuckles. They are usually rusted together pretty good. I knock out all the studs first and then remove the spindles....you'll see.
You may need to fab up a chunk of pipe to push in the seals. I hammer them in through the axle tube(s) Or use threaded rod to push them both in at the same time. The seals are delicate so take your time.
Posting Guru
Joined: Dec 2006
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From: Gladwin,Mi
If you end up tearing it down....they also make a seal for the outer of the axle tube.If you do any kind of wheeling/water crossings ect I would put those in....keep all the crap out of the tubes,they are not that much and worth it IMO if you already have it apart.
Dana 60 Outer Axle Seal [D60-OuterSeal] - $55.00 : Mad 4 Wheel Drive, Bulletproof Offroad Parts & Custom Axle Assemblies
Dana 60 Outer Axle Seal [D60-OuterSeal] - $55.00 : Mad 4 Wheel Drive, Bulletproof Offroad Parts & Custom Axle Assemblies
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Elder User
Joined: Oct 2004
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From: Olympia, WA
Thanks for the feedback fellas. I found an online service manual and quickly scanned through it. Sounds like I'll need to strip the axle down to the housing and pinion just to get to those inner seals. Does anyone know of a good place to get a package deal on a front end service/overhaul kit? It sounds like it would be a good idea to have an entire set of bearings, seals, and ball joints on hand. Depending on the price, I might go ahead and replace everything as long as I'm in there as Cuda suggested.
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Postmaster
Joined: Dec 2003
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From: STEPHENVILLE,TX!!!!!
the shims are under the bearings on the carrier so ya dont have to worry bout that just make sure your races go back on the same side they came out on.
my wifes truck leaks for a bit after the diff oil change then its done, im not gonna spend all the time and money to change them when ya run it a couple ounces low and its fine. i did mine in my truck while i was in there putting the ox locker in!!
my wifes truck leaks for a bit after the diff oil change then its done, im not gonna spend all the time and money to change them when ya run it a couple ounces low and its fine. i did mine in my truck while i was in there putting the ox locker in!!
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Postmaster
Joined: Dec 2003
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From: STEPHENVILLE,TX!!!!!
i dont have a place for a deal off the top of my head just make sure and get timken bearings if ya get new bearings and moog bjoints are about the way to go. the bearings on the carrier and pinon should be fine unless your in 4x4 a ton. i only replaced mine while i was in there doing the locker and i put new gears in.
Postmaster
Joined: Feb 2004
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From: Levittown
Cuda
A big time saver is sawzall the upper and lower joints.
Pull the whole thing out as one. Then rip it down on the bench.
This will allow you to use a press to remove the spindle.
The spindle is the PITA.
Bill
A big time saver is sawzall the upper and lower joints.
Pull the whole thing out as one. Then rip it down on the bench.
This will allow you to use a press to remove the spindle.
The spindle is the PITA.
Bill
Post Fiend
Joined: Oct 2003
Posts: 5,903
Likes: 1
From: MICHIGAN
If you end up tearing it down....they also make a seal for the outer of the axle tube.If you do any kind of wheeling/water crossings ect I would put those in....keep all the crap out of the tubes,they are not that much and worth it IMO if you already have it apart.
Dana 60 Outer Axle Seal [D60-OuterSeal] - $55.00 : Mad 4 Wheel Drive, Bulletproof Offroad Parts & Custom Axle Assemblies
Dana 60 Outer Axle Seal [D60-OuterSeal] - $55.00 : Mad 4 Wheel Drive, Bulletproof Offroad Parts & Custom Axle Assemblies
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Elder User
Joined: Oct 2004
Posts: 782
Likes: 1
From: Olympia, WA
As suggested by a few of you, I jacked up the off side and left it up on a stand with a coffee can under the leaking side knuckle. I'd say I got about a tablespoon out of there in the first 10 minutes and that's about it. I wiggled the axle shaft several times and spun it by hand but it didn't seem to make too much difference. Obviously some fluid got past the seal, so it's not tight at best, but maybe I over filled it. I always fill them till it runs out the plug hole. I'll probably just keep an eye on it for a bit while I shop around for parts and see how bad it leaks before I tear into it.
Laughing Gas
Joined: Dec 2005
Posts: 1,087
Likes: 189
From: Reno, NV
As suggested by a few of you, I jacked up the off side and left it up on a stand with a coffee can under the leaking side knuckle. I'd say I got about a tablespoon out of there in the first 10 minutes and that's about it. I wiggled the axle shaft several times and spun it by hand but it didn't seem to make too much difference. Obviously some fluid got past the seal, so it's not tight at best, but maybe I over filled it. I always fill them till it runs out the plug hole. I'll probably just keep an eye on it for a bit while I shop around for parts and see how bad it leaks before I tear into it.
I used them on my D60 rebuild, but the trucks not quite back together yet so, no personal experience with them yet.
Wish I would of know about the outer axle seal mentioned above... that just makes too much sense!
