609 Front Axle

Discuss Upgrades and Fixes

Moderator: phpBB2 - Administrators

Forum Moderator
User avatar
Posts: 1605
Joined: Wed Jan 07, 2004 8:22 pm
Location: 1550 miles East of Moab

609 Front Axle

Postby broncomarc » Wed Jan 23, 2008 4:20 am

Anyone ever build or have a custom axle built? I'm planning on building a 609 front axle. That's a 9" center section with Dana 60 outers.

Right now the plan is to start with a Dana 60 axle. I've already committed to buy one from a 92 Dodge. Then I'll buy a Spidertrax (or similar) center section. It's pretty beefy and has 3/8" wall 3" tubes.

I can cut the inner C's off the Dana 60 and put them on the 9" tubes, but the C's are set up for 3.125" tubes. The current plan is to cut off the C's with a few inches of tube attached, then have a machine shop turn down the ID of the tubes so a 3" tube would be a press fit into them. This would make the existing tubes act as a sleeve. If this is not a good idea or would cost too much for the machine work the alternative is to buy Dedenbear inner C's, but those are $500!

I would also need to get the hubs redrilled for 5 x 5.5". I will need a different caliper mount, calipers and rotors to fit a 15" wheel.

I'm looking for opinions on this setup... Specifically the mounting of the inner C's. Anyone know of a machine shop that does this kind of work?
- Marc Reiter
1973 Bronco - http://www.broncomarc.com/bronco/

|_________
| /| ,[_____],
|¯¯¯L O-====-O
()_)¯()_) ¯¯¯¯¯ )_)

Extreme Wheeler
User avatar
Posts: 392
Joined: Thu Jan 15, 2004 12:56 pm
Location: Batavia, OH

Postby Jerry Blair » Wed Jan 23, 2008 4:10 pm

Marc,

I cut the outer C off my D60, pressed the tube out of the C and rewelded it back on...no big deal really.

This is similar to what you want to do. I think you might be starting with the wrong D60 axle, though. Is the '92 Dodge a king pin axle (it probably is, but I don't know) If I were you I wouldn't bother unless you use a king pin axle. It is much less expensive to get the king pin style axle set up for high steer than it is with the ball joint axle.

I believe that trying to turn out the centers to make the C's fit will leave much to thin of a sleeve....about 1/16". It might even push out when you try to put it on the axle tube.

I don't know of any shop that does the work. I kept the 8-bolt pattern and big brakes.

Forum Moderator
User avatar
Posts: 1605
Joined: Wed Jan 07, 2004 8:22 pm
Location: 1550 miles East of Moab

Postby broncomarc » Wed Jan 23, 2008 8:18 pm

Jerry, You were just narrowing your 60, weren't you? So the c's were made for that tube. I need to either find C's made for the 3" tube, or find a way to sleeve it. Someone mentioned turning down the tube so the spacer wasn't so thin. This is why I'm asking for opinions. :-)

I'm going to stay with 5 on 5.x so I don't have to build new beadlocks and change out my rear axles and brakes to match... or carry 2 spares for that matter. I just need to redrill the hubs and turn them down a little, get some custom caliper bracket, and use the same rotor and caliper I'm using now.


Below is what the Pirate 4x4 D60 bible says about this axle. I would run it as is, but it's a pass side diff. I was looking for a Ford D60, but then I found they have knuckles that are prone to cracking. The Dodge/chebby knuckles are preferred.


All these Dodge versions were passenger side differential, regular rotation (low pinion) gears, disc brakes, 35 spline inners, 30 spline outers, and kingpin knuckles. 1979-89 versions had external style hubs, with the earlier versions with full-time NP203 Transfer cases having external drive flanges, and later models having external lockout hubs. The external lockout hub bolt pattern is 8 x 3.960". The 90-93 versions had internal style hubs just like the Chevy and lockout hubs. One caution with dodge applications, is you have to be careful to avoid the Dana 61 front axle. 1987-88 and 1991-93.5 Dodge D600 and D700 also came with Dana 61. More info on the Dana 61 later in the article.
- Marc Reiter
1973 Bronco - http://www.broncomarc.com/bronco/

|_________
| /| ,[_____],
|¯¯¯L O-====-O
()_)¯()_) ¯¯¯¯¯ )_)

Extreme Wheeler
User avatar
Posts: 392
Joined: Thu Jan 15, 2004 12:56 pm
Location: Batavia, OH

Postby Jerry Blair » Wed Jan 23, 2008 9:42 pm

Yep...just narrowing. Same C came off the tube that I put back on.

If it were me and I were building a custom axle like yours for a trail rig, here is what I would do:

Go ahead and cut the Cs off the Dodge axle, grind the welds and press the old piece of tube out. Check the fit of the Dodge C on the Spider Nine housing to see how sloppy it is. Probably won't be too bad because it is really close.

If it felt like they were too loose I would run a couple of weld beads (6 or 8) parallel to the centerline of the tube where the C would mount. You could them grind the beads to make the Cs fit tightly to the tube. Set your camber and then weld 'em on. Normally the Cs aren't welded on the side of the tube closest to the tire....only on the side closest to the pumpkin. Add another bead close to the tire and they won't go anywhere.


I think that method would be fine for a street rig too.

I understand where you are coming from with the 5 on 5.5 and the brakes, etc. I would try to do the hubs myself too. I would turn the D60 hub down in the lathe to match the inside diameter of my wheel. Make it close enough that it just barely fits inside the wheel....no play. Then I would clamp my wheel to the hub and use a drill bit in a hand drill the same size as the lug holes. Use the outside diameter of the bit against the hole in the wheel to make a shallow "center" in the hub. Now you can take the wheel of the hub and put the hub in the drill press and use the "centers" to drill your 5 on 5.5 lug pattern.

Flexy Wheeler
User avatar
Posts: 281
Joined: Thu Jan 08, 2004 10:58 pm
Location: somewere in the US

Postby MY87redYJ » Thu Jan 24, 2008 10:55 pm

I know that it souldnt mater but knowing how marc drives I would turn the tube down so not to weld on the cast C's.

go to midwest and ask for Joes Rooks # he is pricey but well worth it. if he cant turn it down it might be able to mill it out, or know someone who can. there is another guy that is very cheep but not sure if he can do it. Tom at Fabco. I think you went there before marc.
its on the road finally only 2 1/2 years later. (note to self before doing work make sure you have the time to do it.)

Extreme Wheeler
User avatar
Posts: 392
Joined: Thu Jan 15, 2004 12:56 pm
Location: Batavia, OH

Postby Jerry Blair » Mon Jan 28, 2008 11:47 am

The C's are cast steel.

No problem welding to them. AND they have to be welded to the tube anyway. The weld beads I was talking about above are to the tube. Essentially making the tube "fatter".

Flexy Wheeler
User avatar
Posts: 281
Joined: Thu Jan 08, 2004 10:58 pm
Location: somewere in the US

Postby MY87redYJ » Mon Jan 28, 2008 8:40 pm

o ok I thought they were like the housings.
its on the road finally only 2 1/2 years later. (note to self before doing work make sure you have the time to do it.)

Forum Moderator
User avatar
Posts: 1605
Joined: Wed Jan 07, 2004 8:22 pm
Location: 1550 miles East of Moab

Postby broncomarc » Mon Feb 25, 2008 9:13 pm

Lookie what I found in my driveway. :biggrin: :biggrin: :biggrin:
Attachments
DSC03054.JPG
DSC03054.JPG (12.26 KiB) Viewed 11081 times
DSC03057.JPG
DSC03057.JPG (14.76 KiB) Viewed 11081 times
DSC03059.JPG
DSC03059.JPG (21.9 KiB) Viewed 11081 times
DSC03060.JPG
DSC03060.JPG (43.61 KiB) Viewed 11081 times
DSC03063.JPG
DSC03063.JPG (21.43 KiB) Viewed 11081 times
- Marc Reiter
1973 Bronco - http://www.broncomarc.com/bronco/

|_________
| /| ,[_____],
|¯¯¯L O-====-O
()_)¯()_) ¯¯¯¯¯ )_)

Master Wheeler
User avatar
Posts: 720
Joined: Wed Sep 28, 2005 9:05 am
Location: Cedar Grove, IN

Postby kesterkamp » Mon Feb 25, 2008 10:44 pm

it looks like the pumpkin is in the middle...
15 Buggy
88 Jeep Wrangler DAD'S
95 Jeep Cherokee DEAD
00 Ford F-250
03 Honda Accord

Forum Moderator
User avatar
Posts: 1605
Joined: Wed Jan 07, 2004 8:22 pm
Location: 1550 miles East of Moab

Postby broncomarc » Mon Feb 25, 2008 11:42 pm

It is, but there's plenty of tube to put the pumpkin on either side.
- Marc Reiter
1973 Bronco - http://www.broncomarc.com/bronco/

|_________
| /| ,[_____],
|¯¯¯L O-====-O
()_)¯()_) ¯¯¯¯¯ )_)

Extreme Wheeler
User avatar
Posts: 392
Joined: Thu Jan 15, 2004 12:56 pm
Location: Batavia, OH

Postby Jerry Blair » Tue Feb 26, 2008 9:33 am

I LIKE it!

I want one of those to replace my rear axle housing......

Master Wheeler
User avatar
Posts: 720
Joined: Wed Sep 28, 2005 9:05 am
Location: Cedar Grove, IN

Postby kesterkamp » Wed Feb 27, 2008 2:22 am

any plans to go wider...?

front first then do the rear?
15 Buggy
88 Jeep Wrangler DAD'S
95 Jeep Cherokee DEAD
00 Ford F-250
03 Honda Accord

Forum Moderator
User avatar
Posts: 1605
Joined: Wed Jan 07, 2004 8:22 pm
Location: 1550 miles East of Moab

Postby broncomarc » Thu Apr 17, 2008 7:33 pm

Here's some eye candy...
Attachments
609-1.JPG
609-1.JPG (52.31 KiB) Viewed 10842 times
609-2.JPG
609-2.JPG (55.5 KiB) Viewed 10842 times
609-3.JPG
609-3.JPG (55.61 KiB) Viewed 10842 times
609-4.JPG
609-4.JPG (54.08 KiB) Viewed 10842 times
609-5.JPG
609-5.JPG (53.5 KiB) Viewed 10842 times
609-6.JPG
609-6.JPG (47.69 KiB) Viewed 10842 times
609-7.JPG
609-7.JPG (39.36 KiB) Viewed 10842 times
- Marc Reiter
1973 Bronco - http://www.broncomarc.com/bronco/

|_________
| /| ,[_____],
|¯¯¯L O-====-O
()_)¯()_) ¯¯¯¯¯ )_)

Extreme Wheeler
User avatar
Posts: 392
Joined: Thu Jan 15, 2004 12:56 pm
Location: Batavia, OH

Postby Jerry Blair » Wed Jun 25, 2008 9:11 pm

Marc,

I was over on the Broncohio forum looking for a ZF 5 speed and noticed you ran in to a problem putting the inner C's on the axle. When I did mine, I heated the inner C in the Oven to 350 degrees for 40 minutes. At the same time, I placed the axle tube in a bucket of ice.

Before removing the C from the oven, get your axle set up and ready to mount. Make sure your "line up" marks are clear on the tube and the C. Then run in the house, grab a pair of oven mits and take the C out of the oven. Run it back out to the axle and you should have a very decent shot of installing it WITHOUT a press. Use a BFH and a block of wood if you need it. It will cool quickly, so you need to work fast.

Once it cools, it will be very difficult to move. HTH.

Forum Moderator
User avatar
Posts: 1605
Joined: Wed Jan 07, 2004 8:22 pm
Location: 1550 miles East of Moab

Postby broncomarc » Thu Jun 26, 2008 7:14 am

I found an easier way to do it. I dropped it off at a machine shop yesterday. :biggrin: To press on the ends and machine out the ID of my rotors to fit over the hubs, they said it would be about $50! Worth it for me!
- Marc Reiter
1973 Bronco - http://www.broncomarc.com/bronco/

|_________
| /| ,[_____],
|¯¯¯L O-====-O
()_)¯()_) ¯¯¯¯¯ )_)

Next

Return to Tech Info

Who is online

Users browsing this forum: No registered users and 1 guest