Lars915 > 1981 Ford Bronco > open folder Front D60 Install

Front Dana 60 fresh off the truck
D60FreshOffTruck.jpg
1681 hits | 97.26 KB | Posted: 12/24/04
Front Dana 60 fresh off the truck
D70U waiting for its turn under the wrench
D70U.jpg
1443 hits | 91.24 KB | Posted: 12/24/04
D70U waiting for its turn under the wrench
First test fit of D70 under the Bronco
D70TestFit.jpg
1316 hits | 64.55 KB | Posted: 12/24/04
First test fit of D70 under the Bronco
Hummer rim waiting for its turn to be refinished. That's a 35 inch tire.
35OnHummerRim.jpg
1336 hits | 58.75 KB | Posted: 12/24/04
Hummer rim waiting for its turn to be refinished. That's a 35 inch tire.
New 42" shoes!
New42.jpg
1384 hits | 58.94 KB | Posted: 12/24/04
New 42" shoes!
Clearance difference between 42"s and 35"s
Compare42-35.jpg
1402 hits | 61.14 KB | Posted: 12/24/04
Clearance difference between 42"s and 35"s
That little bitty tire was on the Bronco when I bought it.
StockTo42.jpg
1572 hits | 61.51 KB | Posted: 12/24/04
That little bitty tire was on the Bronco when I bought it.
First fitup of front axle to see where things will line up. The axle is forward about two inches fr...
AxleSide.jpg
2460 hits | 74.86 KB | Posted: 1/16/05
First fitup of front axle to see where things will line up. The axle is forward about two inches fr...
Front view of initial fitup. Those are stock Bronco rear springs.
AxleFront.jpg
1784 hits | 69.07 KB | Posted: 1/16/05
Front view of initial fitup. Those are stock Bronco rear springs.
This is about the final position for the tire. It'll take quite a bit of trimming to make this fit w...
AxleTire.jpg
2300 hits | 54.59 KB | Posted: 1/16/05
This is about the final position for the tire. It'll take quite a bit of trimming to make this fit w...
Hummer beadlock with the runflat section cut off. A little grinding on the sharp parts and it'll be ...
CutHummerRunflat.jpg
1658 hits | 59.75 KB | Posted: 1/30/05
Hummer beadlock with the runflat section cut off. A little grinding on the sharp parts and it'll be ...
The parts I cut out to build a heavy duty spring hanger.
HangerPieces.jpg
1523 hits | 52.59 KB | Posted: 1/30/05
The parts I cut out to build a heavy duty spring hanger.
All the parts welded up. And yes, my welding sucks.
WeldedHanger.jpg
1652 hits | 52.08 KB | Posted: 1/30/05
All the parts welded up. And yes, my welding sucks.
Both hangers with the welding finished. The one on the left has been abrasive blasted for paint, but...
PairOfHangers.jpg
1649 hits | 41.24 KB | Posted: 1/30/05
Both hangers with the welding finished. The one on the left has been abrasive blasted for paint, but...
Boxed in front frame horn with installed shackle bushing.
BoxedFrameAndShackle.jpg
2025 hits | 57.16 KB | Posted: 2/9/05
Boxed in front frame horn with installed shackle bushing.
These will get nice rounded ends and paint when everything is finished. Length is 6" center-to-cente...
FrontShackleUnfinished.jpg
1560 hits | 46.36 KB | Posted: 2/9/05
These will get nice rounded ends and paint when everything is finished. Length is 6" center-to-cente...
Final mockup of rear hanger. Definitely could have been done better, but OK for a first attempt.
RearHangerFinalMockup.jpg
1518 hits | 60.3 KB | Posted: 2/9/05
Final mockup of rear hanger. Definitely could have been done better, but OK for a first attempt.
The whole spring assembly in place. The front shackle angle is about 45 degrees at ride height.
WholeSpringFinalMockup.jpg
1474 hits | 75.49 KB | Posted: 2/9/05
The whole spring assembly in place. The front shackle angle is about 45 degrees at ride height.
First installation with entire suspension. Now I have to pull it all again for final touch up and pa...
FirstInstall.jpg
1490 hits | 60.97 KB | Posted: 2/12/05
First installation with entire suspension. Now I have to pull it all again for final touch up and pa...
Here the axle is supporting the truck. The shackle angles look good and the pinion angle looks good....
AxleSupportingTruck.jpg
1468 hits | 78.24 KB | Posted: 2/12/05
Here the axle is supporting the truck. The shackle angles look good and the pinion angle looks good....
The axle postion at ride height is about 1 inch ahead of where my SAS axle lined up. I should have a...
AxlePositionAtRideHeight.jpg
1504 hits | 74.55 KB | Posted: 2/12/05
The axle postion at ride height is about 1 inch ahead of where my SAS axle lined up. I should have a...
Close up from the right side.
RightSideCloseup.jpg
1421 hits | 68.7 KB | Posted: 2/12/05
Close up from the right side.
Closeup from the left side.
LeftSideCloseup.jpg
1552 hits | 72.17 KB | Posted: 2/12/05
Closeup from the left side.
Rebuilt and in the truck. Tie rod won't fit above knuckles, have to work on that.
PaintedAxle1.jpg
1468 hits | 65.07 KB | Posted: 2/19/05
Rebuilt and in the truck. Tie rod won't fit above knuckles, have to work on that.
Too bad they don't look like this very long.
PaintedAxle2.jpg
2355 hits | 64.86 KB | Posted: 2/19/05
Too bad they don't look like this very long.
The finished axle and springs. It still needs shocks, brakes, and steering to finish the front end.
RebuiltAxle1.jpg
1647 hits | 61.98 KB | Posted: 2/23/05
The finished axle and springs. It still needs shocks, brakes, and steering to finish the front end.
Another angle
RebuiltAxle2.jpg
1494 hits | 60.24 KB | Posted: 2/23/05
Another angle
First time on the new axles. This should be real close to the final ride height. The axle centers ar...
OnTheNewAxles.jpg
2324 hits | 46.96 KB | Posted: 3/12/05
First time on the new axles. This should be real close to the final ride height. The axle centers ar...
42" tire on Hummer rim. The inner fender is installed in this picture. The inner and outer fenders h...
TireFullSide.jpg
1713 hits | 64.51 KB | Posted: 4/23/05
42" tire on Hummer rim. The inner fender is installed in this picture. The inner and outer fenders h...
This is the clearance between the tire and rear of the inner fender witht tire turned to full lock. ...
RearTire2InnerFender.jpg
1543 hits | 48.2 KB | Posted: 4/23/05
This is the clearance between the tire and rear of the inner fender witht tire turned to full lock. ...
At full lock the rear of the tire hits the spring. Have to adjust the steering stops.
RearTire2Spring.jpg
1364 hits | 47.11 KB | Posted: 4/23/05
At full lock the rear of the tire hits the spring. Have to adjust the steering stops.
This is the clearance between the front of the tire and the inner fender with the tire straight ahea...
FrontTire2RadiatorSupport2.jpg
1288 hits | 50.94 KB | Posted: 4/23/05
This is the clearance between the front of the tire and the inner fender with the tire straight ahea...
At full lock, the tire hitts the front inner fender and radiator support hard.
FrontTire2RadiatorSupport.jpg
1338 hits | 55.53 KB | Posted: 4/23/05
At full lock, the tire hitts the front inner fender and radiator support hard.
At full lock, the front of the tire is also hard into the spring. Have to adjust the steering stops.
FrontTire2Spring.jpg
1440 hits | 58.6 KB | Posted: 4/23/05
At full lock, the front of the tire is also hard into the spring. Have to adjust the steering stops.
This is part of why I chose drive flanges instead of hubs. Hubs would stick out another two inches.
HubStickout.jpg
1338 hits | 36.72 KB | Posted: 4/23/05
This is part of why I chose drive flanges instead of hubs. Hubs would stick out another two inches.
My homemade Zero Rate lift for the front spring. The steering rod will hit the spring when the sprin...
Steering2Spring.jpg
1856 hits | 62.6 KB | Posted: 4/23/05
My homemade Zero Rate lift for the front spring. The steering rod will hit the spring when the sprin...
Loads more clearance after a bunch more cutting and relocating the rad support mount.
ClearanceAfterCutting.jpg
1332 hits | 73.09 KB | Posted: 5/8/05
Loads more clearance after a bunch more cutting and relocating the rad support mount.
Removed a bunch of the radiator support. Hopefully the relocated mount will survive.
RadSupportCut.jpg
1293 hits | 59.45 KB | Posted: 5/8/05
Removed a bunch of the radiator support. Hopefully the relocated mount will survive.
The new body mount sits on top of the frame. There is less beef in the radiator support now, time wi...
RelocatedBodyMount.jpg
1774 hits | 66.62 KB | Posted: 5/8/05
The new body mount sits on top of the frame. There is less beef in the radiator support now, time wi...
With the inner fender reinstalled.
FenderCutFromInside.jpg
1407 hits | 42.3 KB | Posted: 5/8/05
With the inner fender reinstalled.
From the front, the fender is opened way up. I can keep the turn signal, but just barely.
ClearanceFromFront.jpg
1354 hits | 55.27 KB | Posted: 5/8/05
From the front, the fender is opened way up. I can keep the turn signal, but just barely.
If you compare this to previous pictures, you can see how much inner fender is actually removed.
FinalFenderCut.jpg
1527 hits | 67.74 KB | Posted: 5/8/05
If you compare this to previous pictures, you can see how much inner fender is actually removed.
First test drive with new driveline!
OnTheRoadAgain.jpg
2553 hits | 65.56 KB | Posted: 5/9/05
First test drive with new driveline!
I kinda like this one better
OnTheRoadAgain2.jpg
1650 hits | 38.1 KB | Posted: 5/9/05
I kinda like this one better

651 on a 30 degree ramp. Equates to 952 on a 20 degree ramp. The coil / radius arm suspension would ...
FlexSide.jpg
1587 hits | 84.05 KB | Posted: 5/15/05
651 on a 30 degree ramp. Equates to 952 on a 20 degree ramp. The coil / radius arm suspension would ...
Keep in mind that's a 42" tire falling out of that fender.
FlexFront.jpg
1573 hits | 91.37 KB | Posted: 5/15/05
Keep in mind that's a 42" tire falling out of that fender.
The spring goes into slightly negative arch at full stuff. Bump stops will be added to limit travel ...
FlexLFSpring.jpg
1441 hits | 61.34 KB | Posted: 5/15/05
The spring goes into slightly negative arch at full stuff. Bump stops will be added to limit travel ...
There just isn't any more droop in this spring. The tire is barely touching the ground here.
FlexRFSpring.jpg
1504 hits | 71.22 KB | Posted: 5/15/05
There just isn't any more droop in this spring. The tire is barely touching the ground here.
It's amazing these springs have lasted. This is a 6" lift spring. The tire is fully stuffed though, ...
FlexRRSpring.jpg
1416 hits | 76.4 KB | Posted: 5/15/05
It's amazing these springs have lasted. This is a 6" lift spring. The tire is fully stuffed though, ...
Keep trimming 'til it fits
fender1.jpg
1261 hits | 57.8 KB | Posted: 7/2/05
Keep trimming 'til it fits
Not much left
fender2.jpg
1324 hits | 65.92 KB | Posted: 7/2/05
Not much left