Need help with a D60 front axle thump.....
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Senior User
Joined: Jul 2003
Posts: 423
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From: Nova Scotia, Canada
Need help with a D60 front axle thump.....
I have a thumping issue with my Dana 60 front end when it's engaged.....It's a steady thumping sound and it changes with the road speed. I'm 99% positive it's coming from my stub axles at the knuckle. I put new inner spindle bearings in it and stub u-joints when I put the axle under the truck. I can move my stub shafts up and down a lot.....Could it be that I need new locking hubs or maybe something is missing in them like a spring or shims? They are stock Ford manual locking units and they work good but they are pretty rough looking. I'm thinking it's something simple but I've never had a 4wd do this to me before....I don't think it's my differential - It really sounds like it's coming from the wheel ends. 
Mountain Pass
Joined: Nov 2007
Posts: 109
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Don't know why you would have that much slack in your stub axles, but on the thumping when your front-end is engaged, I might have an idea. Is it a ttb axle? I had a similar deal with an older f250 ttb. My problem was the axle shaft and slip joint that come out of the center section of the axle. They were worn enough that they flopped every revolution causing a ruckus when driving with front engaged. You might give it a look. About your stub shaft movement, I take it that you are checking it at the end with the joint. Are checking with the locking hub mounted or off of the hub? How much slack with hubs mounted and in locked position? Did you check the bearing fit on the shaft when you put it together? Just trying to think of some different reasons. My experience with locking hubs is that they don't usully wear out, they break all at once!
