EXCURSION SUPER 60 AXLE BUILD Project Towverlander | Knucklehead Garage
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- เผยแพร่เมื่อ 28 ก.ย. 2024
- This time on Knucklehead Garage we are back in the shop building axles for the Towverlander Excursion Overlander Build. Jamin sourced a Super Duty 60 front axle and matching Sterling 10.5 rear end to build for our Ford Excursion axle swap. We start by tearing them down and regearing with some Yukon 4.30 gears and their Zip air actuated lockers. We then slid in some East Coast Gear Supply 4340 chromoly axle shafts outfitted with 1550 u joints. We then topped it all off with some massive SSBC USA billet brake calipers to slow this beast of a Ford Excursion to a halt with a quickness. A new set of blacked out Warn Manual Hubs allow us to ditch the unreliable stock setup. A Busted Knuckle plate diff cover keeps the front gears safe while a coat of new paint finish these axles off making them ready for install. Next time we will be throwing these axles under the Excursion overland build with some new suspension and a lot of other awesome parts so stay tuned for more.
Front Super 60 Parts List:
Yukon Zip Locker Front $695 - amzn.to/2Z2zuLu
4.30 Gears front $253 - amzn.to/3pc6744
Master Install kit $202- amzn.to/3aT6cUO
BKOR Diff Cover $140- bit.ly/BKOR60cover
ECGS Chromo Axle Set $1300- bit.ly/ECGSchromos
Warn Black Locking Hubs $352- amzn.to/3d0lvxM
SSBC USA Calipers $1398- bit.ly/SSBC60
Rear Sterling 10.5 Parts List:
Yukon Zip Locker $802- amzn.to/3jvHaze
4.30 Gears $337- amzn.to/3cXB1ug
Master Rebuild Kit $240- amzn.to/3aRuPkS
SSBC USA Calipers $1098- bit.ly/SSBCUSA105
Junkyard Axles- $1000
Misc Oil and Parts- $786
AXLE BUILD TOTAL: $9536
Tools:
Seal Driver Set- amzn.to/36XtDLR
Traxion Race Seat $129- bit.ly/TraxionR...
Check out more on this Build:
Build Announcement- • Ford Excursion Overlan...
Engine Build Part 1- • 500HP 7.3 Powerstroke ...
Engine Build Part 2- • 500 HP 7.3 Powerstroke...
#Super60 #Excursion #Overlander
Official Busted Knuckle Merch - www.bustedknuck...
BKF Facebook - / bustedknucklefilms
INSTAGRAM / bustedknucklefilms
SNAPCHAT- / bustedknucklefilms
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AMAZON PRIME- www.amazon.com...
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Busted Knuckle Off Road
5270 AL HWY 69 South
Cullman, AL 35057
United States of America
[ CATCH UP ON THE ENTIRE TOWVERLANDER BUILD SERIES ]
Engine Build Part 1- th-cam.com/video/WzvIbKeehmo/w-d-xo.html
Engine Build Part 2- th-cam.com/video/mjbicPVwBqU/w-d-xo.html
Super Duty Axles Build- th-cam.com/video/mkd_VOoLev8/w-d-xo.html
Coilover Swap- th-cam.com/video/TWa3WvxJnIc/w-d-xo.html
Overland Stuff- th-cam.com/video/F8KN7akP62E/w-d-xo.html
Colorado Trip & Black Bear Pass- th-cam.com/video/gdLj6d0211c/w-d-xo.html
I worked building jet engines in the late 70s and we had baskets to hold dry ice that went over the part and air would blow over the ice onto the part. We also heated the other part. That Excursion is going to be a tank.
Yeah, it’s a pretty common practice in other industries to heat or cool parts with interference fit. Not necessary in this application, but I like to give folks new ideas. 👍
The Break the Bank Tank!
@@BustedKnuckleVideo men and their toys. I’m into UTV and snow machines here in Alaska. I had an airplane once and that will suck your wallet dry in no time.
I enjoy mega trucks as much as the next man but it's very nice to see content on things even I can do at home.
We try to do a good mix of content. Glad you enjoy it!
Time, money, and a few special tools is all you need.
This is what I came here for. Great video!
Glad you enjoyed it!
Glad you enjoyed it.
I’m running the Lee Power Steering kit with a Red Head Steering Gear box in my 7.3L Ex and it cured all the problems. I’m on 35’s, 4.30’s w/ grizzly lockers.
I am looking at lee for my 2000 7.3l
We're you able to run the around the belt radiator hose with that set up?
Do you happen to have a large case alternator? I have both and want to know if it will clear. Thanks
Good parts right there! Stay tuned for our next video. We have a similar setup.
Sounds like the right way to go.
Love the content! Homeboy looks like rob mcelhenny and bert kreischer had a kid. Keep up the good work!!! 🤘🤘🤘
That’s actually a fairly accurate description of my beauty 🤷🏻♂️
HA never heard of any of those people.
Nice. I bought a brand new Dana 50 front axle when I blew out the front end on my F250 years ago. Should have done the Dana 60 conversion. The D-50 is holding up good even with a plow hanging off the front, but the thing still handles like a hay wagon.
yeah the 60 is a nice upgrade for sure
I love everything this channel brings
Do well with commentary, editing, video clips, and all the new awesome buggies with available upgrades. Never seen anything like this before with these buggies and that there was racing events. Im hooked. Keep them coming
Glad you are enjoying it. 👍
@@jaminseat6701 thanks. When watching getting all tensed up watching each individual race. I love it
Thank you very much!
@@BustedKnuckleVideo keep em coming!
@@BustedKnuckleVideo btw i would like to attend one of these events. Im an hour west of Birmingham Al. Any events aroumd this area?
That’s a lot of money all in one video haha awesome!!
you should have seen the first episodes! HA
True, but a lot less than what went under the hood 🤑
Looks expensive with those fancy brakes! LOL im sure its top notch stuff.
This isn't a budget build LOL
@@BustedKnuckleVideo Matt besides your budget Jeep build. Does budget,& off road belong in the same sentence? LOL
Full Spend!
How much for Dana 60 axle for front and rear
@@justaguy9776 not typically
Dang, guys....😕. Coors light ?? I mean, I know we have a budget but, ....we couldn't splurge a little..? It's a suspension vid.. 😒 Nahhhh...just "funnin" with ya buddy..y'all enjoy..👍 I'm doing an Icehouse edge...so. Guys in glass houses..so on & so forth...hell,I'm just enjoying this vid..Y'all keep making em, I'll keep "thumbs -up" ing. them..👍👍
We like high octane beers, but we had to do some math for this one...
Jamin are you bringing some good beer this time?
I agree with the list
it is a solid list
Right between politicians and STDs.
Bad-ass I need that for my excursion
they make great front axle swaps
It’s a totally different truck with radius arms up front.
Sweet piece of steel
Don’t forget the Aluminum binders were out on there 😉
the right mix of steel and aluminum
@@BustedKnuckleVideo Awesome beast of an axle, she won't let ya down 💪👍
Man I wanna straight axle my expedition!!!!!
these would make good axles for that
Start cutting 😉
Need...moar...Excursionnnnnn!!!
I agree. I think I'm going to mail our editor some Red Bull.
do it!
4:15 Chrome Vanadium VS Grade 8 or Better 10.9 Black Oxide Sockets... Oh there is Huge Difference.
Close enough
PMF has some good stuff
Yes they do.
Aluminum!
Barnes 4x4 may have a builder kit
4:02 I have split chrome sockets that say you're wrong.
gotta get the good ones
You can’t tell that boy nothing. He doesn’t use them enough to break them 😂
chrome sockets are impact sockets....
Crome sockets crack to easy with a impact
Not if you have the good ones 😎
Matt can crack any socket.
only steering company i know of for heavy duty application would be psc motorsports
There are others 😉. Stay tuned.
We shall see
Use a balljoint eliminator kit
Those are not meant for the road
What he said.
"Would probably use 4.56s if we were going to tow with it." What's the name of your project? "TOWverlander."
I said "tow with it more." Don't be taking things out of context, this ain't main stream media. Ever re-gear is a compromise based on the intended usage of the vehicle. This vehicle will spend much more time on road trips without a trailer, so 4.30s provide better economy and less engine noise due to lower RPM. If I were going to tow near the maximum capacity very often, 4.56s would have been the better option. Or if I lived at elevation 4.56s would have been better. It's doubtful that I'll ever tow more than 7500lbs with this truck, because that's what a trailer and my Jeep weigh. I have a different vehicle for heavier towing. That being said, having driven it over a 1000 miles with the 4.30s, towing 10K wouldn't be any trouble, but 4.56s would definitely make it a little peppier. I took the opposite approach with my Jeep JKUR. I run 5.13s with 37" tires. Most people would have selected 4.88s for better fuel economy. I like 5.13s because I can load my family and a bunch of gear in it, set the cruise control on 75, and it never hunts for gears. Fuel economy is worse, but the driving experience is better overall. The Jeep needed more gear because the power(torque)-to-weight ratio wasn't nearly as good as this Excursion.
@@jaminseat6701 friend, you don't have to explain gear ratios or justify it to me, it's just a bit of humor.. that being said, i appreciate the reply! I figured with that dog transmission you would have wanted to make it's life a little easier, too. But i completely get not wanting to listen to a 7.3 at 2400rpm or sometbing silly while crushing miles.
I did have one question for you, though.. when you were measuring the backlash.. the pinion was room temp and the carrier/ring were fresh out of the cooler. Does that have much effect on the backlash measurement, or was the backlash done after the carrier warmed up?
Have a good day!
@@Mowk86 The backlash had already been set prior to cooling the carrier and adding the additional shims. As long as you add an equal amount of shim to each side of the carrier, it shouldn't change. Interestingly enough, there was almost zero backlash with it straight out of the cooler. I assume it was from all the frost on the ring gear. Everything was back in spec after it warmed back up to ambient temperature though.
Science !
rzr
I don’t shave 😉
It can haul RZRs
Natty Mechic Brady Martin lol😂😂😂😂
Natty Light?
Nothing wrong with a dana 50 🤦🏻♂️
Nothing wrong with a Dana 50 for what people normally do with an Excursion. But it wouldn’t hold up to what we do. Dana 60 is the only factory option when switching to coils though. Even if I’d stuck with leads up front, I’d have swapped in a D60.
It's 10 better than a 50 duh!
So far my dana 50 is holding my 40’s under my Jeep.
@@alpinesupra88 if it’s working for you, keep on trucking 👍
@@jaminseat6701 Y’all just need to quit digging the axle without even giving it a chance, but more parts for me should I need them. 🤙🏼
You want to know why we keep coming back and watching y’all. It’s bc this is how it actually happens haha; it’s why it’s so much better than the trash they put on TV. Love the videos guys, keep’em comin
Thanks man. We make mistakes like everyone else. Might as well get a laugh out of them.
The never ending axle build. Should take 2 days....2 months later....
This is the second time I watch this I love this build or you're going to show where you did the coil conversion on the front that would be a great video thanks love all your videos 😎
Coming soon!
@@BustedKnuckleVideo cool thanks
@@BustedKnuckleVideo get that editor some Red Bull.
Damn! Im'a West coast guy with a 2001 Excursion which i call my "Baby". But these guys got some serious talent! Of course, most folks will never know the mechanics, geometry, and skill-set required to build smthng like this. I aint no mech, but i find programs like this fascinating. Thinking of joining and buying a subscription. 👍👍👍👍👍
Glad you enjoyed the build. We had some amazing adventures out West in it.
I love the build and am doing a very similar one, but I don't understand swapping your hubs to manual... The factory hubs are vacuum AND manual, so if your vacuum system failed, you always have a manual turn as a backup. Not only that but ngl I do like the convenience of not having to get out to lock your hubs, expecially here in Canada in -30 🥲
Manual hubs are more reliable plus these Warn ones are stronger than the factory ones.
@@BustedKnuckleVideo True, I suppose having it in the middle of nowhere on a trail, you don't have the option of having your hub fail lol... The Excursion looks great! I love the coil conversion alot!
The Warn Hubs are stronger, more reliable, and better looking. The Factory Hubs are prone to sticking in the on position. Also, sometimes I don't want to be in 4LO, I only want to be in 2LO, and full manual hubs gives me easy control over that.
@@freedomworx That's a very good point! Never thought about the 2-Low!
Your steering options are:
1) build an Over The Knuckle steering with offset 1 ton TREs and
2) machine 1 or 2 knuckles for high steer.
Weld on high steer kits ask for larger wheel sizes and only run heims. Any other options post them bellow...
We do have a BKOR weld on high steer kit...
Wish I would have come across your videos before I had my axle gears done. I may have missed it. But what gears and tire size are you running? I wound up going 4.56 w/ 38” tires. I really wanted to do a coil suspension swap but just lifted the X 6” lift.
What does something like this cost?
I absolutely love this series. Both because it's right in line with how I'd do up an Excursion, and because Jamin is hilarious.
Don't give Jamin the big head HA
@@BustedKnuckleVideo don’t bust my bubble
freezer for race and some heat to housing and it damn near falls in.
But dry ice makes fog 😂
Fail
Hahaha rust falls between polititions and STDs!!!!!!
None of them are good for you 😉
It's the truth.
You should have gotten a Dana super 60 out of a 2017 and up super duty because those super 60 have a 10" ring gear 35 inner and out axle splines 3.5" axle tubes 1550 steering ujoints and bigger bearings this is the axle I used in my solid axle swap duramax...but I'm surprised you guys didn't use ball joint deletes
These are pretty dang tough and plenty good enough for this build.
Super 60's did not come out until 2017. 2005 is a Super Duty HD 60. Then is a Big Difference.
We prefer the super duty ones
I think this is not super 60 . It just super duty dana 60.. very big difference for people looking for info about true super 60
Super duty 60
The Ford air actuated hubs work great. You just don't have the proper seal driver. Thats where the issues come from.
ahhh, well atleast they work manually
Please let me know the type of steering box you recommend, I have a 2000 excursion two wheel drive thanks
Can’t go wrong with Lee power steering
Awesome video! Can't wait to see the install!
Hope to finish shooting that this weekend.
Coming soon!
Soooo
Since you have replaced everything on those axles, have you saved and money over some speciality axles?
Definitely
For sure. You would have to buy all of the same parts for a set of custom axles, plus the custom axle housings themselves, which is much more expensive than this set of junk yard axles. These bolt right in, and there really is nothing to gain from a custom housing on this project. Custom housings do have their place, but not for this project.
Love the Super 60 build video! gave me some great ideas!! I did the RedHead on my excursion... they offer pre-tapped ports for hydraulic assist if you want to go that far... i didn't but i've been happy. Had it in for 2 years and steering tightened up and still feels new. Get a new power steering pump though. that's on my list for sure. Saginaw makes a "almost" drop in that looks tough
I already had a Red Head Steering gear in the truck. Just installed an amazing new steering system; stay tuned for the next video(s).
@@jaminseat6701 can't wait!!
when will that video be out?
@@BustedKnuckleVideo good question...
got axles and a 10.5inch 4link coilover kit from a junkyard 2007. this helps me see the amount i need to spend to get it under there and functioning. Also want to watch you put them on and just repeatedly reference that haha
Axle install and coilover kit is next
@@BustedKnuckleVideo buying your merch now then
Sounds like a legit junkyard.
great video. this dude is funny as hell. have him do all the vids.
Jamin has his moments HA
@@BustedKnuckleVideo I'm going to need a raise if I do all the videos.
What is double of nothing?
@@BustedKnuckleVideo I think that means I start paying you...
You said that the beginning of the video that you had special tools to do this job that you didn't have to resort to pressing bearing on and off and that the tools made the job easier. Unless my cough medicine kicked in and I blacked out I did not see anything different than the way this has been done for at least the last 50 years since I have been into cars and trucks. You even use the Frozen trick to get things back together. Only difference you had used dry ice others use freezers. Myself I buy cases oh can air turn it upside down and I'm able to cool off any thing that I need to. This is very useful when doing heads.
Don't get me wrong I enjoy watching you work. I would just hoping to see a different way of doing this. I have no problem with how you did this it's exactly the way I do it except for dry ice.
I do look forward to watching more of your videos. I'm getting ready to watch what you did with a bronco. I am Ford blue all the way I even still have my 1990 Ford F-150 5.0 4x4. Have no intentions of ever giving that up.
I most definitely gave you a thumbs up and subscribe. I figured that the least I can do for all the videos that you have made and put out there to help others doing the same work.
we don't always do things the right way but we have fun with it
Awesome product to help with those leaky vacuum seals is a grease coupling that bolts right in there and serves a way to grease the unit bearing. Both Barnes4wd and RiffRaff diesel make a version of equal quality
good call
Part numbers for calibers please
link should be in the description, If not let me know
@@BustedKnuckleVideo thks mate i can't find it im in Bakersfield California im Australian Jewish Chinese Mexican LOL
@@peterhatch1583 do you even speak metric Bro? 😉
There's the Beef.....
Grade A!!!
All of it
Axles. Yum.
They look good now
Professional install 😂
Nice axles boys!
We do what we can 👊🏻
Thanks! 👍
2:31 10 Better.....Papa johns 😂😂
Edit-Better axle,bigger gears.....papa johns..........10 better 🤣🤣lol
It’s a good pizza value (with a coupon code).
Better Axle. Bigger Gears. Super 60.
I prolly built them 60s lol I work at Dana Corp
there are a bunch of them out there
Do you guys make a busted knuckle sticker like you had on the XJ?
We sure do they are on our webstore www.bustedknucklegear.com
I have split chrome sockets tightening lug nuts. I should say OVERtightening lug nuts.
Me too. Matt is just wrong.
Needs better sockets...
Show more videos of this excursion build
Working on the next one now!
Jamin needs to hurry up with the build process LOL
Any interest in doing another excursion?
heck no! LMAO
@@BustedKnuckleVideo ha! 10-4 hard to find anyone who wants to do a 2 to 4wd swap on these things.
we just build projects for fun. Not for hire.
Understand completely. Definitely not fun doing the same thing twice.
I wouldn't mind stripping one down for drag racing.... World's Quickest Excursion!
Idk what your doing wrong but when I do axles theres a lot more dirt and grime. There's always a moment when you kneel on a rock and your definitely saposed to hit the back of your hand with that sledge.
There was plenty of dirt and grime when I started.
sounds like he is doing it right
The first differential I ever rebuilt was also the 2nd and 3rd differential I ever rebuilt.
Learn the hard way
That’ll happen 😂
And how works that brakes driving into highway and city? Grettings bro!
work great
Work great and look great. I'd hate to have to stop this tank with the factory binders.
Hey I need to throw some questions your way. Pulled the wheel off to change the hub assembly and realized the seams for the auto 4wd were shot.
the seals?
@@BustedKnuckleVideo yes sorry. That surround the cv where it enters the knuckle
@@justinbranden5275 those are called Super Duty Donuts 😂. They all fail. The hubs will still work fine in manual mode. Those seals are really only needed for the vacuum actuation system. You can replace them, but I think you need a special tool to get the depth correct on them.
How does the new SSBC 6 pot front and 3 pot rear setup perform over stock?
the brakes are amazing. It slows down the 37s like stock tires.
It’s been so long, I don’t even know how many pistons I have. But it stops pretty well for a 5 ton truck!
Damn I want to put lockers on my 04 CHEVY 2500HD. How easy do you think that would be ?
Might be a little more difficult with the IFS, but I’m sure it’s doable.
depends on your skill level
I agree with you on them 17 inch tires I wish I was rich I would have you build my truck
I blew the budget on this one 🤷🏻♂️
@@jaminseat6701 it was worth every penny I’m dreading the cost of fuel I’m sure it’s going to go up not happy with my V 10 getting 9 miles to the gallon
@@joekatz7819 we don’t build trucks for hire and for good reason 🤣
WARREN! Lol. I feel like that'd also be me.
I mean it’s spelled Warn. War-n...
@@jaminseat6701 It was hilarious
So many people say it that way.
Mechanical comedy I love it. You guys make this stuff fun to watch.
Thanks. If you can’t be correct, you might as well be funny.
Jamin is funny sometimes.
Why would you have to rent those tools working in that shop?
We try to do it the way a normal guy/gal would do it, when they don’t have access to a full race shop. That’s why we don’t use the vehicle lift in the shop.
exactly
I love these big dana axles. I put a 2005 front axle axle on my 99 2wd dually and I love how they ride.
good call
4wd Conversion?
@@freedomworx yes
You should make another channel that you showed us the full builds and not just the Finnish Ed product
this was the full build of the axles?
I know but like a few videos ago you just showed us the finished thing on the black one
@@tripixfn9319 oh you are talking about the buggies. Our production builds are the same so we just show the finished product. We will be doing a video on how we build the chassis soon.
I’m sorry 😂😂 I should have been more clear the first time but I’ll be waiting on the video on how to build the chassis
Any tool in a shop is a professional tool
Does that make me a professional tool? 😉
Semi-Pro
Not sure if it helps but I did put the full front suspension, axil, radius arms, coils and steering from a 2016 F550 on my 2000 F350. The "Super 60" has much larger knuckles, balljoints, breaks, U joints and a different carrier. It is substantially larger than the regular Dana 60 from the F250/350 variant. It was trial and error as some parts work on both but many parts weren't even close. FYI
It wasn't a bad swap. We are buttoning it up now.
@@BustedKnuckleVideo Yup, mine got difficult when I decided to use everything up front. I also went with the Carli Unchained suspension. It uses the longer leaf springs in the rear so I also had to relocate the spring perches and shock locations. I really love the turning radius you gain by removing the front leaf springs. Yours looks like a fun build.
@@eclifton4070 can’t wait for everyone to see the finished product. It turned out killer!
I know there are differences, but most people just say "Super 60" for any 60 that comes out of a 2005+ Super Duty. For our application, this standard "Super Duty 60" is fine, because we upgraded the brakes and went to 1550 joints anyway. Everything else is plenty strong.
@@jaminseat6701 I agree and it would take some serious abuse to really need the F450/550 version. I went that route more for the curiosity of it and the 450/550 axle is wider with a steeper turning radius. With my military super single wheels, I needed the extra width. You will love the difference from the leaf spring steering angle, as it is still much better than the Dana 50 with leafs.
Do you sell the covers or was that a one off
Diff cover? Link is in the video description.
yes we sell the covers at www.bustedknuckleoffroad.com
Have a question. I have a 2005 excursion. I have been having issues with my axles. I run a 305 tire on my ex and the front shakes a little and I have change the front axles and u joints, brakes and rotors but still shakes. What does this set up cost to do? I really think that the axles that I have are no cutting it.
This axle build was around $10k. Have you checked your Ball joints and suspension bushings as well as the track bar?
@@BustedKnuckleVideo yes I have changes all those components. New ball joints, u joints, axles, brakes, rotors, wheel hubs, new everything. Nothing.
@@tntruckin5112 when does it shake?
@@BustedKnuckleVideo in the front axles when I get to 65 mph.
Have you moved the tires around to eliminate them? I've had similar issues with old tires.
Needs more rust
Jk
Matt’s XJ has enough rust for all of us 😂
I cut most of that off....
@@BustedKnuckleVideo the rest probably fell off in Moab.
how much though???
All of it. 🤑
All pricing is in the description
Que the argument over the definition of "Super 60"
I’ll grab my popcorn.
No bites on that one yet.
@@BustedKnuckleVideo probably just not a popular enough channel to get in the big trolls.
Luckily this isn't a big channel like bleepin Jeep. 😮😮😮. Jk don't hit me.
@@jake1021 😂
@@jake1021 🤣🤣🤣
👍👍👍👊👊
Excursion is gonna look good on those!
очень познавательно .
🧐
google translate?
Was that a cracked cap seal
Cap seal?
U joint Not sure if it was just grease or the seal at the open side oft the cap was torn. “Cap seal”
@@Wheelingoffthewrench gotcha. No, it was just grease. 👍
Nice. I’ll be cleaning up a set of 2003 f350 axles for my Jeep
lots of grease