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Home/ Registry/ Ford/ Bronco/ 1987-1991/ 1990 Bronco/ Rebuilding Johnski's D60 supermotors.net/registry/7660/33746

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Rebuilding Johnski's D60

From 1990 Ford Bronco, documented by Dave Blaney.

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1990 Ford Bronco - D60 rear in all it's glory 1990 Ford Bronco - Open carrier removed 1990 Ford Bronco - The chunk, w/ stock 4.10 gears 1990 Ford Bronco - Went out and bought 1/2" drive to 3/4" adapter, machined 180 thousandth's off of 1 5/16 inch socket so it would fit inside the yoke to remo… 1990 Ford Bronco - Stock gears 1990 Ford Bronco - Old pinion bearings and races and shims 1990 Ford Bronco - Bare D60 housing with pinion bearing races driven out. 1990 Ford Bronco - Necessity is the mother of invention, I cut out these little wedges on the bandsaw to keep the axle housing fom trying to rotate while I wa… 1990 Ford Bronco - Perfect contact patch 1990 Ford Bronco - Close-up of a differential gear set, showing the teeth of the ring gear. 1990 Ford Bronco - Gotta love the simplicity of a full spool. 1990 Ford Bronco - Close-up of differential gears within an open housing, showing part number 103027. 1990 Ford Bronco - Other side of ring gear contact patch, also perfect. 1990 Ford Bronco - Home made torque arm to allow one person to torque the pinion nut. 1990 Ford Bronco - If you cross your eyes this pic will look less blurry. 1990 Ford Bronco - Motorcraft part number for VSS sensor 1990 Ford Bronco - Blurry pic of VSS sensor. 1990 Ford Bronco - Ford part number for tone ring 1990 Ford Bronco - Tone ring 1990 Ford Bronco - This tooth has got to go, ground it off. 1990 Ford Bronco - New spool all set up with new ring gear, ring & pinion set up is complete. 1990 Ford Bronco - Tone ring in place. Note it is a little big, in fact there is a 80/1000" gap between the tone ring and the spool. 1990 Ford Bronco - I tried several different ways of spacing the tone ring evenly around the spool, ultimately I settled on taking 4 left over 30/1000" shims… 1990 Ford Bronco - Frankenstein's ring gear...actually I was concerned with getting welding slag in the bearings, so I wrapped them in damp towels just prior… 1990 Ford Bronco - One welded on tone ring. By the way, it ended up being centered within 2/1000" using this method.