Hello, I am new to this so please forgive my mistakes, this is what I have.

03 Excursion with a busted Dana 50, so I purchased a 2002 Super Duty Dana 60 with all the fixings and I am trying to fineness the shimming. I have the Maintenance manual for this truck but I do not see a very detailed section on
I replaced the axle shaft seals and pressed on the new inner pinion bearing, there was a .050 shim between the pinion head and the bearing (#21), however I now have a pack of (.050) shims behind the inner setup race (#19), then the new (same .016) oil slinger (#11) behind it.

Continuing back I have a used crush sleeve to let me just get the pinion almost tight for the first reading, I have a setup outer pinion bearing (#17) and the new race (#10) is pressed in. I have 6 crush sleeves since I heard I may do that a few times.

On my carrier it had on the bolt side four .011 and a .005 shims to make .049. Tooth side had two .012 and two .010 to make .044.

I replaced these with the exact thickness after cleaning them of oil and measuring in three spots. I placed them behind two more setup bearings (#29) and the new races (#2).

I painted three spots on the ring gear and turned it with resistance. Photo below to show the pattern. Also, I had .006 backlash on the carrier.

I wasn't able to measure any movement for preload on the carrier, I don't have a spreader and used a soft rubber mallet to seat the races fully. This is what I saw a guy on YouTube do and said that's about how he sets it up. I would prefer a more scientific way to know it is done correctly. This is what I have so far.

Any advice is appreciated, I will be out in the shed all weekend doing this. Thanks in advance.




1st pattern with .049 Bolt / .044 Tooth. .050 on the pinion.

 

I just went through my Dana 60 with new ring, pinion, and bearings. Took me forever, so I know what you're going through.

Are the shim values the same as your old setup? Is that how you decided on them?

What's the backlash value?

Some will say the pattern needs to move back toward the center of the tooth, but Dana's own documents say a pattern towards the toe as you have it there is correct. This is about how mine looked and it came out perfect - no binding, noise, or heat.

Be sure to check the coast side as well.

Here's my thread, includes the Dana doc reference.. https://www.ford-trucks.com/forums/1...rn-thread.html