maybe368

Ok. following the Thrashingcows lead, I thought to add this on the first page of this thread in case it vaporizes or gets attacked by a zombie apocalypse:

https://web.archive.org/web/20170702...g-pins-290373/ ...Mark






Ok guys and gals, I decided to do a how to thread on replacing your Upper king pin and renew all of the bushings and seals on a 4x4 dana 60 for our Dodges. I am working alone and had nobody to take pics, so I did not take any disassembly pics. I didn't want to get my camera dirty. This will be an assembly thread, but all you need to do is start at the bottom and reverse this for disassembly.

I did mine one side at a time, but you could raise the whole front and do both sides at once. Always use safe practices, like eye protection and good, sturdy jack stands. NEVER GET UNDER A VEHICLE SUPPORTED BY A JACK ALONE. I am only going to talk about the work from after the removal of the hub and disc assembly. This is covered in a great BC847 thread in the sticky Here https://www.dieseltruckresource.com/...d.php?t=143024.

Now that I talked about how to start, now I am going to jump to the other end and talk about the install. Just reverse this for disassembly.


Make sure that all parts are clean and ready for installation,

http://www.flickr.com/photos/63170901@N03/5760330840/http://www.flickr.com/photos/63170901@N03/5760330840/ by http://www.flickr.com/people/63170901@N03/, on Flickr

Makes sure that the lower king pin bearing cup seat is clean and ready to accept the new bearing cup:

http://www.flickr.com/photos/63170901@N03/5760332176/http://www.flickr.com/photos/63170901@N03/5760332176/ by http://www.flickr.com/people/63170901@N03/, on Flickr


During disassembly, the old bearing cup needs to be driven out, but retain the old cup for use during reassembly. I hit the lower cap from the top with a hammer to start the cup moving, then used a stout punch to drive it out.

Remember to put the cap in first:

http://www.flickr.com/photos/63170901@N03/5759788755/http://www.flickr.com/photos/63170901@N03/5759788755/ by http://www.flickr.com/people/63170901@N03/, on Flickr

then the bearing cup:

http://www.flickr.com/photos/63170901@N03/5760332070/http://www.flickr.com/photos/63170901@N03/5760332070/ by http://www.flickr.com/people/63170901@N03/, on Flickr

Tap the cup in as evenly as possible. If you have the correct drift, use that, but carefully tapping works:


http://www.flickr.com/photos/63170901@N03/5760332472/http://www.flickr.com/photos/63170901@N03/5760332472/ by http://www.flickr.com/people/63170901@N03/, on Flickr

You can use the old cup to fully seat the new cup, but be sure to put the thicker side down (very important):

http://www.flickr.com/photos/63170901@N03/5760332558/http://www.flickr.com/photos/63170901@N03/5760332558/ by http://www.flickr.com/people/63170901@N03/, on Flickr


The old cup will be stuck No worries, clamp a pair of vise grips on the thick side of the old cup and drive off with a hammer:

http://www.flickr.com/photos/63170901@N03/5760332788/http://www.flickr.com/photos/63170901@N03/5760332788/ by http://www.flickr.com/people/63170901@N03/, on Flickr

Works every time:

http://www.flickr.com/photos/63170901@N03/5759789329/http://www.flickr.com/photos/63170901@N03/5759789329/ by http://www.flickr.com/people/63170901@N03/, on Flickr

I then used a punch to make sure it was well seated. You can now use the old cup to drive in the new seal. Put the freshly packed lower king pin bearing, after greasing the cup, then the seal. Drive it in until it firmly seats:

http://www.flickr.com/photos/63170901@N03/5759789475/http://www.flickr.com/photos/63170901@N03/5759789475/ by http://www.flickr.com/people/63170901@N03/, on Flickr


this is getting long, so I am going to post this and continue in a reply

maybe368

Continuing with lower:

http://www.flickr.com/photos/63170901@N03/5759789551/http://www.flickr.com/photos/63170901@N03/5759789551/ by http://www.flickr.com/people/63170901@N03/, on Flickr


http://www.flickr.com/photos/63170901@N03/5759789625/http://www.flickr.com/photos/63170901@N03/5759789625/ by http://www.flickr.com/people/63170901@N03/, on Flickr


Lower bearing and seal all done:

http://www.flickr.com/photos/63170901@N03/5759789759/http://www.flickr.com/photos/63170901@N03/5759789759/ by http://www.flickr.com/people/63170901@N03/, on Flickr

Upper king pin installation and disassembly tools:

http://www.flickr.com/photos/63170901@N03/5760333546/http://www.flickr.com/photos/63170901@N03/5760333546/ by http://www.flickr.com/people/63170901@N03/, on Flickr

http://www.flickr.com/photos/63170901@N03/5759790215/http://www.flickr.com/photos/63170901@N03/5759790215/ by http://www.flickr.com/people/63170901@N03/, on Flickr

Apply blue locktight to threads on new upper king pin (edit: I wanted to be sure and I find that red locktight is recommended on the pin, so use red locktight hereMark):

http://www.flickr.com/photos/63170901@N03/5760333820/http://www.flickr.com/photos/63170901@N03/5760333820/ by http://www.flickr.com/people/63170901@N03/, on Flickr


Thread it in, mine seated by hand:

http://www.flickr.com/photos/63170901@N03/5759790431/http://www.flickr.com/photos/63170901@N03/5759790431/ by http://www.flickr.com/people/63170901@N03/, on Flickr

http://www.flickr.com/photos/63170901@N03/5759790567/http://www.flickr.com/photos/63170901@N03/5759790567/ by http://www.flickr.com/people/63170901@N03/, on Flickr


Put the hex wrench in and drive it in with a hammer:

http://www.flickr.com/photos/63170901@N03/5759790655/http://www.flickr.com/photos/63170901@N03/5759790655/ by http://www.flickr.com/people/63170901@N03/, on Flickr

Continued...

maybe368

place big breaker and hex socket:

http://www.flickr.com/photos/63170901@N03/5760334240/http://www.flickr.com/photos/63170901@N03/5760334240/ by http://www.flickr.com/people/63170901@N03/, on Flickr

Place super long cheater, this one is 8' made of 1.5" square tubing with 1/4" wall thickness:

http://www.flickr.com/photos/63170901@N03/5759790823/http://www.flickr.com/photos/63170901@N03/5759790823/ by http://www.flickr.com/people/63170901@N03/, on Flickr

This is how far it tightened:

http://www.flickr.com/photos/63170901@N03/5759791013/http://www.flickr.com/photos/63170901@N03/5759791013/ by http://www.flickr.com/people/63170901@N03/, on Flickr

Remove hex with vise grips and hammer. PB Blaster and heat may be necessary:

http://www.flickr.com/photos/63170901@N03/5759791117/http://www.flickr.com/photos/63170901@N03/5759791117/ by http://www.flickr.com/people/63170901@N03/, on Flickr

All done:

http://www.flickr.com/photos/63170901@N03/5759791197/http://www.flickr.com/photos/63170901@N03/5759791197/ by http://www.flickr.com/people/63170901@N03/, on Flickr

grease king pin:

http://www.flickr.com/photos/63170901@N03/5760334978/http://www.flickr.com/photos/63170901@N03/5760334978/ by http://www.flickr.com/people/63170901@N03/, on Flickr


Hang knuckle on upper pin:

http://www.flickr.com/photos/63170901@N03/5759791587/http://www.flickr.com/photos/63170901@N03/5759791587/ by http://www.flickr.com/people/63170901@N03/, on Flickr

Place seal with opening up:

http://www.flickr.com/photos/63170901@N03/5760335294/http://www.flickr.com/photos/63170901@N03/5760335294/ by http://www.flickr.com/people/63170901@N03/, on Flickr

http://www.flickr.com/photos/63170901@N03/5759791971/http://www.flickr.com/photos/63170901@N03/5759791971/ by http://www.flickr.com/people/63170901@N03/, on Flickr

Continued:

maybe368

Use a blunt object to seat the seal in the bottom:

http://www.flickr.com/photos/63170901@N03/5760335404/http://www.flickr.com/photos/63170901@N03/5760335404/ by http://www.flickr.com/people/63170901@N03/, on Flickr

Grease the upper bushing, note the tab on the bushing for placement:

http://www.flickr.com/photos/63170901@N03/5759791749/http://www.flickr.com/photos/63170901@N03/5759791749/ by http://www.flickr.com/people/63170901@N03/, on Flickr

Place the bushing with the tab located in the slot in the knuckle:

http://www.flickr.com/photos/63170901@N03/5759791809/http://www.flickr.com/photos/63170901@N03/5759791809/ by http://www.flickr.com/people/63170901@N03/, on Flickr

place gasket:

http://www.flickr.com/photos/63170901@N03/5760335470/http://www.flickr.com/photos/63170901@N03/5760335470/ by http://www.flickr.com/people/63170901@N03/, on Flickr

place spring retainer:

http://www.flickr.com/photos/63170901@N03/5760335564/http://www.flickr.com/photos/63170901@N03/5760335564/ by http://www.flickr.com/people/63170901@N03/, on Flickr

Place spring:

http://www.flickr.com/photos/63170901@N03/5759792285/http://www.flickr.com/photos/63170901@N03/5759792285/ by http://www.flickr.com/people/63170901@N03/, on Flickr

Locktight bolts:

http://www.flickr.com/photos/63170901@N03/5760335784/http://www.flickr.com/photos/63170901@N03/5760335784/ by http://www.flickr.com/people/63170901@N03/, on Flickr

Place upper cap, but leave bolts loose for now:
http://www.flickr.com/photos/63170901@N03/5759792511/http://www.flickr.com/photos/63170901@N03/5759792511/ by http://www.flickr.com/people/63170901@N03/, on Flickr

Continued:

maybe368

lube lower king pin and locktight bolts:

http://www.flickr.com/photos/63170901@N03/5759792625/http://www.flickr.com/photos/63170901@N03/5759792625/ by http://www.flickr.com/people/63170901@N03/, on Flickr

place lower king pin:

http://www.flickr.com/photos/63170901@N03/5759792697/http://www.flickr.com/photos/63170901@N03/5759792697/ by http://www.flickr.com/people/63170901@N03/, on Flickr

Tighten evenly and torque to 70 to 90 foot lbs:

http://www.flickr.com/photos/63170901@N03/5759792803/http://www.flickr.com/photos/63170901@N03/5759792803/ by http://www.flickr.com/people/63170901@N03/, on Flickr

Evenly tighten the upper cap bolts:

http://www.flickr.com/photos/63170901@N03/5760336300/http://www.flickr.com/photos/63170901@N03/5760336300/ by http://www.flickr.com/people/63170901@N03/, on Flickr

Torque to 70 to 90 foot lbs:

http://www.flickr.com/photos/63170901@N03/5760336392/http://www.flickr.com/photos/63170901@N03/5760336392/ by http://www.flickr.com/people/63170901@N03/, on Flickr

At this point you can reconnect the tie rod end to the knuckle.

Continued:

maybe368

Now to prepare spindle and axle shaft:

http://www.flickr.com/photos/63170901@N03/5760331684/http://www.flickr.com/photos/63170901@N03/5760331684/ by http://www.flickr.com/people/63170901@N03/, on Flickr

Thoroughly lubricate the spindle needle bearing, inside the spindle and place the seal with the open side out (away from needle bearing):

http://www.flickr.com/photos/63170901@N03/5759789859/http://www.flickr.com/photos/63170901@N03/5759789859/ by http://www.flickr.com/people/63170901@N03/, on Flickr

http://www.flickr.com/photos/63170901@N03/5759789965/http://www.flickr.com/photos/63170901@N03/5759789965/ by http://www.flickr.com/people/63170901@N03/, on Flickr

lubricate shaft:

http://www.flickr.com/photos/63170901@N03/5760336498/http://www.flickr.com/photos/63170901@N03/5760336498/ by http://www.flickr.com/people/63170901@N03/, on Flickr

Place spacer an shaft with the bevel towards the u-joint. Lubricate the inside of the larger seal and place it on the shaft:

http://www.flickr.com/photos/63170901@N03/5760331796/http://www.flickr.com/photos/63170901@N03/5760331796/ by http://www.flickr.com/people/63170901@N03/, on Flickr

http://www.flickr.com/photos/63170901@N03/5760331862/http://www.flickr.com/photos/63170901@N03/5760331862/ by http://www.flickr.com/people/63170901@N03/, on Flickr

Slide the hub onto the shaft:

http://www.flickr.com/photos/63170901@N03/5760331962/http://www.flickr.com/photos/63170901@N03/5760331962/ by http://www.flickr.com/people/63170901@N03/, on Flickr

Put antiseize compound on axle shaft flange:

http://www.flickr.com/photos/63170901@N03/5760336598/http://www.flickr.com/photos/63170901@N03/5760336598/ by http://www.flickr.com/people/63170901@N03/, on Flickr

Install shaft, It only goes on 1 way:

http://www.flickr.com/photos/63170901@N03/5759793219/http://www.flickr.com/photos/63170901@N03/5759793219/ by http://www.flickr.com/people/63170901@N03/, on Flickr

Continued:

maybe368

Install The caliper support and brake shield, locktight the threads and torque the nuts to 50 to 60 foot lbs:

http://www.flickr.com/photos/63170901@N03/5760336780/http://www.flickr.com/photos/63170901@N03/5760336780/ by http://www.flickr.com/people/63170901@N03/, on Flickr

Here you need to install the rotor/hub assembly, caliper, brake pads and 4x4 hub assembly, see sticky for instruction on this:

http://www.flickr.com/photos/63170901@N03/5760336878/http://www.flickr.com/photos/63170901@N03/5760336878/ by http://www.flickr.com/people/63170901@N03/, on Flickr

This is a pic of my old, right, upper king pin. You can see the unusual wear:

http://www.flickr.com/photos/63170901@N03/5760331148/http://www.flickr.com/photos/63170901@N03/5760331148/ by http://www.flickr.com/people/63170901@N03/, on Flickr

Here is a pic of the springs and how worn and compressed they are:

http://www.flickr.com/photos/63170901@N03/5759787957/http://www.flickr.com/photos/63170901@N03/5759787957/ by http://www.flickr.com/people/63170901@N03/, on Flickr

I hope this helps anyone attempting this job, it is very rewarding and nothing feels better than having a good suspension under you ...Mark

Fibrestar

Great write up, Doesn't look that scary now. Thanks

maybe368

Thanks, I was very worried about this job, but it was not as bad as I thought, one just needs to apply a little pressure via large tools...Mark

maybe368

When I cleaned up the right side parts I found that the bushing had failed completely and was no longer supporting the spring evenly. This is demonstrated by the deformation of the steel spring retainer. This side is much worse than the other and I hope that this was the cause of my death wobble problem.

http://www.flickr.com/photos/63170901@N03/5762225375/http://www.flickr.com/photos/63170901@N03/5762225375/ by http://www.flickr.com/people/63170901@N03/, on Flickr

Mark

BC847

Stuck.

maybe368

Cool, I feel honored, Thanks Mark

92'1stGen

Very nice. I'll be starting on this this weekend.

maybe368

Thanks, I got to checking and I found lower king pins here: https://www.wfoconcepts.com/cr/Dana-60/3172 and have 2 of them ordered up. I am going to replace them with the wheel still on, just jacked up. I thought they were not available any more. When I get them, I will post the pics. I am not going to drive the truck until EVERYTHING is new...Mark

farmer0_1

nice work takes all the mystery out of it. thanks