Dana 60 Swap Made Easy (XJ One Ton Swap)
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- เผยแพร่เมื่อ 29 เม.ย. 2021
- Installing a complete swap kit designed to simplify a Super Duty Dana 60 swap into a Jeep XJ/TJ. The kit from Barnes 4wd will make swapping a Dana 60 into your Jeep quicker and easier.
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Great job love this content , definitely needed in the the off-road community
I've been waiting for this. Excited to see what's coming for the rear
That looks like a well made product
Thanks for sharing your knowledge! Very good video!!
👍
Nice video !!!!!! I saw your off camber event on your buddies Chanel and i must say you handled it vary well !!!!!!!!!!!
Can't wait to see it in action! 💪🏼👍🏻🇺🇸
Me too. Still have a ton of work and money to throw in it
That looks Badass Robbie!!!💪💪
Thanks Dan!
That's definitely a kit I'm ganna want to get soon
Looks great man! You are a more patience man then me, letting it cool! I'd be constantly peeking!
Haha. Went and did 6 hours of yard work while it cooled
@@MuddyBeards4X4 Now thats a productive day!
Wow, beefcake. I was considering this swap, as my d30 looks like a toothpick since I went to 36" tires. Thanks for the great video & info.
Holy crap. I’d be shocked if you haven’t broken anything yet since you posted this. Lol
@@ryanskenard Broke my steering box after an 18" drop off a rock. Axle shafts are still holding up.
nice work
Looking good man!
Awesome!!!! That was i need to my ZJ but here in Portugal the dana 60 are practically nonexistent so i need to get other solutions.
That's too bad man. Used to be easy to get here, but they are getting harder to find
Looking good. Only thing I would recommend would be moving your ground with your weld. Get it closer and on the same side of axle you are working on, this way the arc doesn't have to travel throughout the whole axle. I was always told closer the better for ground and arc.
It doesn't matter that much actually, moving it closer helps more with magnetism and such
@@kingturd35 it matters greatly and takes seconds to move. But you do you.
DANG SON!
On the half moon pieces you’d think they would just notch it and not cut it out completely, that way you could just hammer it down and weld it.
👏Very good DIY how to video! I was curious about your lower control arm mounts width. Are those lower control arm mounts wider then stock xj control arm bushings width and aftermarket ones as well?... do you know how wide?
Looks great. Super beefy!
🐃🥩
Looks like the shock mounts are upside down. Unless you are planning something different.?
Cutting off the cast link bushings on the 2005+ axle is a pain in the asss
Haha i have heard the 05+ are more work to prep
What year ford was your 60 out of?
I migged right on to the cast with alot of preheat and it worked fine
Same here, except on a damn Dana 30 HP🤣
@@SarahSmith-hd8kd mine was a 78 ford hp44 front, c gussets. and a truss on 60 rear
@@FlawedOffroad I just finished building my 77.5 f250 Hp44 last weekend. It goes in as soon as the wheels get here on Wednesday
@@SkyBlueOffRoad mines in and wheels are on but I have no fuel tank, brake lines, steering and some other stuff yet
Are the "C"s made out of cast steel? Is there a need to pre-heat them before welding the lower control arm bracket on?
Do yall think i could use this same truss with a dana 80 dually rear axle?
How do you like the barnes truss? I’m trying to decide between barnes and artec but artec is sooo expensive
Hey great video i was wondering what blanket do you rap the axle in.
It's just a fiber glass welding blanket
Is this kit for both front and rear? Lmk
Thay need to make one for the dana 60 in a jeep grand cherokee wj
This kit should work for a wj. The front suspension of an XJ and a WJ are very similar
Will Johnny Joints fit into those upper mount sleeves in lieu of the bushings like they do on the factory axle?
Yes, but there are different sizes for the mounting brackets and joints so make sure they are the same width.
Just curious how you obtained the material type of the cast section? If it were cast steel it would be an easy mig job. Many automotive parts now days are simply cast steel. I don't know about that part though is why I ask!
My research concluded the center section is cast nodular iron. Many people pre and post heat and MIG it right up, and many people have no issues and some do get cracks and failures. From a structural stand point in my opinion it would be best to use a process that is designed for dissimilar and cast materials
What heck are your plans for you XJ? Trussing a D60 is..........????
What type of welder and setup are you using? Can this be done with me flux core mig welder?
Yes you can use flux core mig run it a bit hot. As far as the cast differential welding you can buy a stainless steel wire with proper flux core.
Certified Welder-fitter 1973. pipe fitter welder for 30 + yrs experience.
Did you weld your axle tubes to the center casting?
No I think the truss will be enough to prevent the tubes from spinning
Do you have to run long arms with this or will a good short arm setup still work
It should work with short arms. It's designed to swap straight into the factory setup
Does anybody sell bare housing with truss welded on and ready to go at reasonable price
Good thinking applying primer for rust prevention there's nothing better than a porus paint product for that ... This is like looking at guys who drive around a work in progress vehicle with body work filler exposed or painted with fiat paint to protect from moisture .
How much would it hurt if you didn't weld the cast?
With the stress of the upper mount and the limited surface area on the short side tube I would recommend welding to the cast material to be extra sure that truss stays stuck on there
What Mig welder do you have?
Its a Hobart 190
what are the cons of the 99-04?
30 spline outer vs 35 with the 05+. The knuckle design is a bit different too. I wanted it because they are considerably cheaper up here in the pnw for the 04's. Also the 04 is about 4 inches narrower and that was what I was looking for
What size tire are you going to running?
I got some 40x13.50 maxxis razors
Why didn’t you do coilovers in the front to match the rear? Also what year are your axles from?
Just expensive and I didn't want to cut up the front end for now. I was hoping to get it back on the trail quicker by staying coil sprung up front as well. The axles are out of an 04 super duty
@@MuddyBeards4X4 any plans to swap over to coilovers? I’m looking at doing this swap. But on the fence if it’s worth it to do coilovers or just keep springs
I mean eventually maybe. But for the cost benefit I am staying coil sprung for this build
Curious what your wheelbase is with this install and your rear 4 link?
The 04 super duty 60 is 69' wheel base. Which is wide but not as wide as the 05+. Here is the link for the 4 link rear www.youtube.com/
@@MuddyBeards4X4 69” is the track width, I was curious of your wheelbase, center line of front axle to centerline of the rear axle measurement. Stock a XJ is around 101 inches.
Gotcha man. I am not sure where it will land. Rear is stretched about 6 inches. And front will be pushed forward an inch or two. So 108 range
@@MuddyBeards4X4 thank you very much. I didn’t know if the Barnes super duty swap moved the front at all. Great video have a great day
It does not move it, I am just going to adjust the arms. But I wish swap kit had offset (or adjustable) coil pads so that you could correct the coil. I had my axle pushed forward about 2 inches previously and had a decent curve on the coil
Is this a full width axle or was it narrowed?
Full width
@@MuddyBeards4X4 Thank you for the response. I have an '03 Superduty with a bad motor. Been really considering the 60 and Sterling swap for my 2000 2 door xj. This truss looks to be just what I need
Your shock mounts are on upside down...
this aint muddy beards
How so?
What a pain in the ass