Dana 60 cross pin removal?

[idahoyj]

I am trying to install a LockRight in my front diff tonight. I cannot get the pin loose that holds the cross pin in place. This seemed like a pretty easy project, but I am really struggling with this pin.
Any tricks? Since its soaked in gear oil, I'm surprised that it is seized up in there. Can I heat the carrier a little and hope the expansion lets the pin loose? Or will that damage the carrier?

 

[I Lean]

It's just a roll pin, you need to drive it out with a fairly thin punch and a hammer. If you use a punch that is too small, it will try to force itself inside the roll pin and expand it rather than pressing it out. It only goes one way, so drive it from the ring gear side out toward the not-ring-gear side. (there's a little shoulder inside the hole)

 

[idahoyj]

Thanks for the help. Last night I was using a punch that was too large diameter. This morning after reading your post, I switched to a smaller diameter and it was easy to move the pin. But my punch was too short to get the pin out far enough. I ended up sacrificing an old screw driver and cut the handle off to finish driving it out.

Now, I can't get the spindle off. The nuts weren't too hard to get loose, but I cand get the spindle to move at all. I'm soaking it in WD now, hopefully with a BFH and a block of wood, it will come loose later.
Any suggestions or tricks for that?

 

[Toad]

Spindle tool and slide hammer

 

[idahoyj]

I rented the tool with slide hammer. My hands are numb from what seems like a million strokes on the slide hammer. But it's still stuck on there.
Before I got the tool I tried-
Putting a jack under the spindle and with all of the Jeeps weight on it, I whacked it several times, but nothing.
I have WD40 and PB blaster on it, but nothing.
I have knocked several 2x4s to splinters on this thing, but nothing.
I tried a little heat at the flange of the spindle, but nothing.........

Tomorrow I will get a bolt that fits in the end of the tool, and run it in against the end of the axle shaft like a pulley puller would. Maybe that will do something? That and soaking all night in PB blaster?
Any orther suggestions????

 

[I Lean]

Spindles can be stubborn. Use a hammer and drift to hit the back side, hammer sideways/up/down on the spindle to start loosening it, use the little recess on the side to get something in there to start loosening it---as soon as you have any gap between the spindle and the knuckle, you can drive a chisel in to pry it out farther. Work it back and forth, alternating sides.

You do have all the nuts removed holding the spindle on, right? (gotta check the dumb stuff...)

Last question--why were you removing the cross shaft before the carrier is out of the housing?

 

[STAG]

Try knocking the spindle studs out too if you can. (Don't ruin the threads). Also, you dd not mention if it was a kingpin or balljoint 60, if it is a kingpin maybe just try removing the lower kingpin cap and bearing and removing the whole knuckle. Then you can use a shop press to press the spindle out if you still want to.

 

[idahoyj]

Spindles can be stubborn. Use a hammer and drift to hit the back side, hammer sideways/up/down on the spindle to start loosening it, use the little recess on the side to get something in there to start loosening it---as soon as you have any gap between the spindle and the knuckle, you can drive a chisel in to pry it out farther. Work it back and forth, alternating sides.

You do have all the nuts removed holding the spindle on, right? (gotta check the dumb stuff...)

I totally understand checking the dumb stuff. Its amazing how easy it is to overlook things like that. But yes, they are removed.

Last question--why were you removing the cross shaft before the carrier is out of the housing?

I took the cross shaft out to remove the spiders and I need the axle shaft out to remove the side gears. I'm not planning to remove the carrier. I am installing a Lockright "locker".

Try knocking the spindle studs out too if you can. (Don't ruin the threads). Also, you dd not mention if it was a kingpin or balljoint 60, if it is a kingpin maybe just try removing the lower kingpin cap and bearing and removing the whole knuckle. Then you can use a shop press to press the spindle out if you still want to.

Im working on a balljoint axle. I will knock the bolts out tonight and give it another try.

As you can probably tell, I'm new at this..... So I really appreciate all of the suggestions.

Do you think pushing against the axle shaft with a bolt through the spindle puller will damage the shaft etc?? Im hoping with the pressure against the spindle, I can hammer and pry it loose at the same time.

 

[idahoyj]

Dana 60 front spindle removal

Finally!
I used the spindle adapter for the slide hammer and ran a 1/2" fine thread bolt into it against the axle shaft end. A couple good whacks with the hammer while the pressure was applied, and it slipped right off.
Now, hopefully I can figure out how this all goes back together.........?:-\

 

[thenag]

Glad to hear you got it. I think I had as many issues the first time I put that thing in. I actually had to pull the carrier and have a shop get the cross pin out.

What has worked well for me to get the spindles off is an air chisel, it just seems to vibrate them right off. I put a flat chisel between the spindle and knuckle nd just work it around.

Nathan