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More progress on the old Dana 60. Disassembled everything and cleaned up the outside. Lots of dirt and rust came off. It will be painted with epoxy chassis paint when the axle is finished.

The first step in the process it to make a case spreader. I designed my own, based on the original tool. The Allen head bolts fit into the holes in the differential case.

Man, this thing is filthy on the inside. A black goo of metal and old gear oil has coated the inside.
When I got the truck, it seemed like the 1965 gear oil was still in there. Sure left its mark on the components. The pinion bearings are funnily enough OK, still a lot of small indentations in the races of debris in the oil. The carrier bearings are shot. The non ring gear side has small pits from debris, but the ring gear side bearing has extensive spalling and the bearing also spun on the carrier itself

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Forgot to take a picture! Will do it later.

Luckily the damage is not too bad, it could have been worse...
Time to repair the carrier. Planning to make a sleeve to repair the damaged surface. Will continue tomorrow.

Then I can use the old bearings as setup bearings, and start the ring and pinion installation.

For fun, I checked the gear pattern before pulling the old carrier. The backlash is way out of spec, but the pattern isn't too bad considering its age.

As you can also see, one of the pinion preload shims came out broken. The pinion oil slinger was also damaged (not by me!) Maybe I got a Monday morning differential?