dana 60 axle question

[scout man]

I was trying to track down an issue today on my Ford Superduty and I came across an unexpected issue. I was adding fluid to the rear axle when I noticed a lot of metal on the magnet. I opened up the housing and found this (see pictures) One entire shim managed to come loose and grind up in the gears. I suspect this has actually been this way for a while. Surprisingly, the gears look immaculate. 186,000 miles on them and they look brand new still. I suspected this could be the cause of a vibration I was tracking down, but that ended up as a bad u-joint (see picture 3 - this is what the needle bearings looked like in one cap, non-existent in the one across from it). Anyways. when I put it in reverse the gap opens up how it is in the picture, when I put it in a forward gear and creep forward it mostly closes up that gap. Is there anyone on here who likes to play with gears and wants to re-set up this axle? I am really not sure how on earth this would have happened either. Not what you suspect to fail in a gear setup.

alright, tried on 2 different browsers and cant get the pics to load. I will try again later.

[Patrolman]

Steve, get some pics or a video. Sounds like there could be a problem if you have a noticeable gap changing.

[scout man]

oh, i know there is a problem. Just stunned the gears arent showing it. Here are the pics, finally got them to load. second one is a close up of what you see in the first one. I need to look at the schematics for the axle though, as there are definitely no shims in this location in a dana 44. Not as familiar with the 60s. Not sure why you would have shims here, or why there are like 2 inches of them.

[Patrolman]

Looks like this is a limited slip? Did the chunks come from in there? Not surprised if they are, as limited slips eventually wear out. Also, are those gear marks on the case? Looks like the pinion gear is possibly rubbing on the case. If that is the case, the pinion gear may be loose. Bad pinion bearings are the likely cause, but pinion shims could be an issue too.

[Popsgarage]

Looks like this is a limited slip?

I think you're right, Jeff. One of the clutch discs came apart! That may be why you don't see any damage. Some of them are a friction material and that is probably what let go.

[Haku]

Here is a exploded diagram of a Front Dana 60 that is pretty clear...

http://www.pirate4x4.com/tech/billavista/Gear_Setup/images/Figure_9_2400-90.jpg

It is also a little weird to me that they used so many shims, but I guess that is what it takes sometimes. I haven't read through it fully, but this article might be of use in figuring out what is going on and how many shims might be approriate... http://www.pirate4x4.com/tech/billavista/Gear_Setup/

[Robert B]

to me that does look like a LS diff and not an open one .... the open one you can see into much more and yes when under load especially creeping those will move and try to move both wheels ...........not sure if it will work on an LS but jack it up put it in low gear let it run and try to hold one tire still open do it and some LS diffs especially ones with extra clutches stuffed in them for more traction this might not be doable.........again this might not work because they work on torque and friction but it might ...........anyway that really does not look like an open case..... and last time I looked ball joint 60s are basically identical to 44s just bigger

[Robert B]

heres what I know open diffs to be

[Brucker]

Looks like this is a limited slip

X1000 or whatever we are up to now.

[scout man]

interesting. I looked different than I expected as well, but there were definitely spider gears inside the housing. Like, standard spider gears just like my dana 44s. It would make sense to me for it to be friction plates though. I couldn't figure out why any shims would be needed in that location. I would assume then that the limited slip is no longer functional without that plate? I would assume this is true, since I am fairly confident it is not currently functional, since I never new it was there if it was a limited slip. Seems like more research needs to be done! I don't think those are teeth marks Jeff, but now that you point it out it does look that way. Didn't notice them at all in person though.

[scout man]

According to my axle code it is a limited slip with 3.73 gears. So its probably safe to assume that this is not going to cause problems in the axle since I got the pieces out? Probably the limited slip wont function (apparently they sucked anyways) but no damage is likely to occur?

[Brucker]

You should be fine to leave it alone.

How often have you changed the diff fluid? When doing so, have you been using a LSD additive with the fresh oil?

[scout man]

today was the first time I have changed it. I have only owned this truck a year.

[scout man]

oh, and apparently its a sterling 10.5, not a dana 60.

[scout man]

thanks for the help guys! Some day when I have money I want to put a selectable back there anyways, so I will just let it be for now!

[gm4x4lover]

Steve you have an f350 correct? I bet that isn't a dana 60 but rather a viston (spelling) 10.5. The limited slips commonly fail as do the pinion bearings.

[scout man]

It's a 250,but yes, you are right about the axle. It's a sterling/viston 10.5