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Here is a parts list of what was used on both of the Dana 60's for the Wrangler.
Dana 60 rear std rotation from a 1979 Ford F-250
LABOR
Dana 60 front reverse rotation from a 1985 F-350 crew cab single wheel diesel
After building the front and rear axles, the rear diff cover received a custom rock guard fabbed out of 3/8 steel. The rear axle was then rolled under the Jeep to begin a mock-up positioning to set the 1degree pinion angle at the spring pads, and to take measurements for the anti-wrap bars.
Here's a shot of the anti-wrap bars after fabrication and a coat of paint. They use tapered urethane bushings and ½ grade 8 hardware at the rear.
The cross member was welded in place between the frame rails after much thought and planning with the final positioning to facilitate future transfer case removal or upgrade.
Here is a shot of the completed torque arm from the rear.
The rear springs are fresh front Wrangler springs. The front springs are designed to carry more weight than the rear from the factory, but have no arch with weight on wheels. This means they will droop and compress with almost equal travel, while the extra factory spring clamps aid in killing axle wrap. Jody plans on having us build a complete roll cage and rear Baja-type spare tire mount for the 37 in the near future, so the heavier spring will be a plus This shot shows the integrated shock mount/spring plate built out of 3/8" plate with 9/16" diameter u-bolts secured the axle to the springs.
With the rear axle completed, it was time to start on the front First step was to remove the front axle assembly and it's components.
Since the entire suspension was to be fabricated, Jody wanted a front shackle reversal built. First the spring center width had to be changed to match the axle due to the spring pad being machined into the differential housing on the driver's side. Once the spring bucket width was determined, the frame supports for the front suspension were built.
Instead of building a generic rock-type bumper, we decided to build a slider to increase the front approach angle and to ease the effort required to bump up and over large boulders. The front slider incorporates the shackle reversal, and ties the frame ends together.
Here is the deck completed, with accommodations for a future winch. Hot out of the bender, came the front rock guard tubes. This provides protection from rock for the entire front sheet metal area, but allows obstacles to pass without hanging up so the Goodyears can take a bite.
The custom front spring pack was coated with graphite paint to aid in articulation without sacrificing load carrying capacity. The spring are much longer than stock Wrangler springs to provide awesome droop and complete compression.
Here's Mr. Clean finally making a wish come true, sawing off the O.E.M. steering arms from the knuckles, in preparation for the high steer parts.
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