Dana 60 axle E locker mods by BSF Recovery Team

[Music] hi there welcome again to uh our bsf recovery team uh dana60 axle build videos i realize that uh this is getting to be a little long and drawn out uh that's not intended uh it's just because i have a lot of information that i want to share with you i've seen other people's build videos and there's a lot of details that they kind of skip over that some of you might know but others might not so i feel like i should share all those details with you makes the videos a little bit long and drawn out i apologize for that but bear with me we'll get to everything so uh we have to make some modifications to this housing i realized before we do i forgot to pop the outer pinion bearing and seal out so we'll do that right now okay one of the modifications we have to do so we have to drill through the housing so we can put our wires through for our e-locker now the instructions are kind of generic uh they aren't specific to the dana 60 it doesn't tell you exactly where to drill the hole what it does tell you to do is to set the differential in there uh in its bearings and figure out a good spot to drill a hole we're going to take our setup bearings here and put them on the differential uh i'll tell you all about setup bearings later but basically our setup bearings are just a set of bearings that'll slip on by hand and slip off by hand now we'll take the carrier over there set it into the housing and so we can see where we need to drill the hole for the wires okay our eating locking differential is in the housing uh the tabs that hold the magnet are uh just above and below the cap bolt holes here and our wire is right here so let's grab a light here and take a look now our vent hole is right here that's where our vent is and it looks like we can drill that right beside or just up the ramp from our vent looks like that would be a pretty good spot i would put it right i don't know if you can see that they will put it right about there let's look at it on the outside so it looks like we should drill a hole right about here so grab a center punch and mark that so that's where we'll drill the hole directions say a half inch hole but before we drill the hole we're going to take our differential out because we don't want to get any metal shavings in our differential we'll start out with a little bit smaller bit work our way up to a half inch [Music] so [Music] there we go that should be the hole we need [Applause] the next modification we're going to do is we're going to drill a hole here and put in a drain plug it doesn't have to be very big uh we got a little quarter by 18 drain plug here uh we do want to use a flush mounted plug because there's a good chance that this differential is going to be scraping over some rocks and stumps and stuff so we're going to drill in and put in this flush mounted quarter by 18 national pipe thread uh plug here first thing is we're going to pick a spot center punch it now the chart says for the quarter by 18 national pipe thread we got to drill a 7 16 hole we're going to start out a little bit smaller and work our way up make it easier [Music] [Music] okay now up to 7 16. [Music] now to help our tap start straight we're going to taper the end just a little bit okay we got a quarter by 18 national pipe thread tap here that's a tapered tap [Music] i've got it started straight a little lubricant there's a lot of dialogue here that has great potential for some sexual innuendo drop a comment if you feel the need i like a good laugh i remember pipe threads are tapered and we actually drilled a straight hole so as we go in it gets tighter and tighter but we want to tap it deep enough so the plug is flush but we don't want to run the tap all the way through like you would on a normal thread the reason we go a little bit and back it up is so we cut a little metal and then as we back it up it breaks off the burr of the metal that it's cutting that way we don't jam up our tap okay it's sticking through a little bit now we'll take it out and we'll see how deep our plug goes it's still sticking up a little bit a little bit more than we want it to we want it to be virtually flush so we got to tap a little bit deeper okay let's check it again look at that it's recessed just a little bit i like that so we're going to stop there it's not a real big hole but it doesn't need to be just big enough to let the fluid out all right this is why we did this with the differential empty and no bearings in there see all those metal shavings now we got to clean those out all right since we're at it now is good time to drill our third hole for our spring bolts so we have our plate that we already modified we cut the bump stop off of the top and uh drilled it with a half inch hole this is off of the old axle and we'll bolt it in place here a few lock washers because the spring isn't there so we don't want to bottom out these bolts in the holes and pull the threads but we want to bolt it in place so we drill the third hole in the right spot so [Music] doesn't have to get bolted very tight [Music] now our modification uses a half inch bolt here we don't want to drill the housing with a half inch hole because we need to cut the threads into it but we're going to use a half inch bit to mark the hole now there should be a dimple there that we can drill with the smaller drill bit and there we go right where we need to drill a hole so the drill size for uh half inch uh national course threads is uh 2764 i think that's right yes 27 64. but again we're going to start with a smaller drill and drill a pilot hole now we are concerned about how deep we drill this hole so we're going to measure it and see how far down we are um we know we can go down at least as far as this pad right here so the pad is 1.182 down so we've got a ways to go yet [Music] all right let's check it now and we're 1.3 we're a little bit down into the below the pad here but that's fine now we'll drill it to the uh 27 64 well that one ain't very sharp all right now we can cut our threads being careful to start the tap nice and straight again some lubricant okay feels like we hit the bottom that doesn't mean we've cut threads fully all the way to the bottom if you look at the tap here the tip of the tap is tapered so what we want to do now is we want to run down through there after we clean out the hole with a bottoming tap the bottoming tap what's that well basically that's a tap that's just cut off you can make your own by taking an extra tap and cutting it off square just after the taper ends on the tip all right let's make ourselves a bottoming tape now we'll go uh square that up on the grinder and uh just touch each little cutting edge just a tiny bit to help it start right now we should be able to cut threads all the way to the bottom of the hole or pretty close to it that should do it okay now that we got those modifications done we can clean up our housing we want to make sure that we have no metal debris inside also we're going to pop the inner axle seals out before we give it a good cleaning and then we'll be back to assemble the differential thanks for watching the sf recovery team stay tuned for the rest of our dana 60 axle build and e-locker install for the record keep wheeling be safe out there and maybe we'll see you in the woods [Music]

Channel: recoveryteam

Views: 11,122

Rating: 4.9793816 out of 5

Keywords: Dana 60 axle, eaton e-locker, BSF recovery team, BSF garage, 4x4 wrecker front axle, Dana 60 front axle, dana 60 axle build, 4x4 wrecker, off-road wrecker, off-road tow truck, 4x4 tow truck, recovery truck axle build, e-locker mods, eaton locker install, e-locker install, 4x4 tv, off-road tv

Id: xd6Tv-l5kVs

Length: 16min 4sec (964 seconds)

Published: Tue May 04 2021