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Old November 11th, 2009, 03:36 PM   #21
camccardell
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taking it a step further.

how do the splines of a 14 bolt compare to the sterling and the dana 60?
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Old November 12th, 2009, 05:18 PM   #22
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Originally Posted by camccardell View Post
taking it a step further.

how do the splines of a 14 bolt compare to the sterling and the dana 60?
14 bolt is coarse 30 spline 1.5 inch with a 7,000 ft lb torque rating. Dana 60 is fine 30 spline 1.31 inches and has a torque rating of 4,500 ft lb. Dana 70's have 1.5 inch 35 fine spline with a 10,000 ft lb torque rating. I've never seen the ratings posted for sterlings, but being extremely similar to a Dana 70, I would believe it would be rated around the same.
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Old December 8th, 2009, 03:08 PM   #23
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so it begins...

I have cut the ends off a 03 sd axle.





I threw one on the vise and started cutting along the weld



After I cut it clean I could see where the tubs seperated from the inner c. It looked kinda like a crack. I'll post a pic when I do the other side.

Anyway, got me a 20 ton press from ol harbor freight and I had alro steel cut me a 1 inch piece of a 3 1/2" bar for a slug.

I ground down the sides and used it to press out the tube.



After a few good pulls... Presto!

and here is the piece and the knuckle





I started on the other one and killed my other angle grinder. I killed the old one when I was cutting the first C and hoped to get through the 2nd, but no luck.



Oh well....

So the tally so far to remove these things....

2 cases of beer for the old housing
$100 for the chop saw to cut the ends off the old axle
$200 for the 20 ton press
$35 x2 for the angle grinders
$10 in cutoff discs
??? in electricity and about 5 hours of my life and assorted beers....

hmmm, I am starting to wonder if I should have just bought new ones, lol
The is really starting to cost me, but hell at least I can keep the press and the chopsaw!

Last edited by camccardell; January 13th, 2010 at 09:12 PM.
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Old December 9th, 2009, 03:37 PM   #24
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went to wally word last night, and killed 2 new grinders in less than 5 mins!
So to hell with it, I'm gonna go buy a real one. I predict a dewalt in my future.
Anywho... I need some measurements guys. I need the measurement of a 90's dana 60 from the center of the middle C to the the other center.
I want to make sure I don't cut off too much of the tubes of the sterling.
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Old December 9th, 2009, 03:45 PM   #25
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So to hell with it, I'm gonna go buy a real one. I predict a dewalt in my future.
Milwaukee grinder FTW
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Old December 9th, 2009, 04:15 PM   #26
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Metablo grinder FTW
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Old December 9th, 2009, 10:52 PM   #27
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What did you decide for inner shafts being that 60 shafts won't mesh into sterling carriers?
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Old December 10th, 2009, 12:23 PM   #28
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well..... I guess I'm going to make some myself for mock up.
Need to get to a lathe and I'm gonna cut the stock 10.5 shafts and some broken d60 shafts for the yokes, and turn 1 down and bore out the other. After I get the legnth spot on, I'll probably have em made.
I called moser and they will make a set for me for some $

I still cannot find the steering knuckles I want...
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Old January 8th, 2010, 08:08 PM   #29
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anyone out there have any idea on where I can get a set of custom side gears?

I want to get a set of sterling gears cut for d60 splines.
Mige be cheaper than custom axleshafts, and then again it might not be. Thought I'd at least check it out.
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Old January 8th, 2010, 08:32 PM   #30
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the way I see it, the only benefit of a sterling 10.5 (vs other 1 tons) is the huge wheel bearings, which are only utilized in a rear application.




but on the other hand, big points for creativity
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Old January 10th, 2010, 01:40 AM   #31
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calling auburn on monday. they might have same size internals between the d60 and the sterling. Might be able to get a sterling unit with d60 sides.

Fingers are crossed...
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Old January 13th, 2010, 09:18 PM   #32
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i have done it!

anyway, the weather was nice today, so I began to stip down the sterling axle.



had one hell of a time getting the rusted on parking brake off, but a hammer and a fw gratifying swings of the ol BFH knocked off some of that lovely rusty crap



Finally got off all the brackets and accessories, as well as the axle shafts and the hubs.



Without a torch, things were going slow with the angle grinder, but I did get the leaf spring perches off today.





If I'm not working tommorrow, I am going to take off the ends of the axle tubes and start mocking it up for the inner C's
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Old January 16th, 2010, 06:49 PM   #33
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Well what and educational experience I had today...
My chop saw bit the big one, so I had to drive over to battle creek. They were cool and replaced it no prob and gave me a free 2 yr warranty.

Anyway, I got the caliper bracket off and made some space in the garage and moved everything in out of the cold.



Here is a shot of the spindle. I made my cut right on the shoulder of it to maximize the tube I would have to work with.



1'st mistake

Too much material, took forever to cut through. Not only that I didn't measure properly, so trying to save the tube was pointless. It just isn't long enough. It was about 2 and a half inches too short.

Guess I shoulda set it up to use the 79 legnth axleshafts instead of the 90's series ones.



I did however get the drivers side cut properly. It actually looks rather good, I just wonder if I am going to have enough material to weld the brackets for the coils and arms.





well, I went back to the passenger side and cut off an additional 3 inches, hoping to get into the meat of the tube and out of the spindle.

The weld bead was easy to see on the inside, so I cut back 1" from that. I am going to have to sleeve the tube anyway so who cares about a few more inches right?

I chopped it off and ground the hell out of it for good penetration.



Well, mistake #2 the inside of the tube is only 2 and 13/16 in diameter. The other side is exactly 3" in diameter, so what the hell?

Well I cleaned out the metal shavings and saw it. There is a little bit of a shoulder in there. guess I need to take off an additioinal inch and a half.



I will cut the tube down tommorrow and cut a piece out of the other side and get them both ready to weld.
I'll have to wait till monday to get some 3" .250 wall tube

Last edited by camccardell; January 16th, 2010 at 08:18 PM.
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Old January 18th, 2010, 12:58 PM   #34
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Well this project has come to a complete standstill.
I would like to the thank the idiots at the sterling axle plant and ford for making a complete piece of junk.

I'm not sure how to sleeve something that is a friggin oval.



it is about 3" at the widest point, and a hair under 2 7/8 at the thinest.

Called alro steel and 2 7/8 .250 wall is gonna cost me around $100.

so I guess I need to find someone with a lathe and make some from the old d60 tube.

maybe I can make a 3" slug, wrap it in sandpaper and attach it to a drill and go to town!

if you can help, please let me know!

Last edited by camccardell; January 18th, 2010 at 01:03 PM.
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Old January 19th, 2010, 10:03 AM   #35
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Maybe a cylinder hone?
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Old January 19th, 2010, 10:10 AM   #36
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cut the plug welds and remove the old tube and retube with the right length.
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Old January 19th, 2010, 04:03 PM   #37
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if you can make it work, that will be one cool custom front axle, cool idea
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Old January 19th, 2010, 06:27 PM   #38
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well, I would love to cut the welds and press in new tube, but I have 2 problems.

#1 no cutting torch, and no one around me seems to have one.

#2 even if I rented one or bought one, how in the hell would I press out the tube? I seriously doubt that my 20 ton press could do it.

If anyone out there can help me with this, please let me know, as this is the preferred methood.

called advantage drive line, and they told me it's a no go.

found me something cool as hell last night though.

Shur-Brite star discs. I contacted them and they are sending me a few samples, and I called production tool supply and also have some ordered. they are designed to grind or polish the inside of a tube.
Not too sure about it, But I'll give it a try.
http://www.pts-tools.com/cgi/CGPTSRI...=02_05_003_005

Also got me a 6ft legnth of 2-7/8 tube yesterday as well, so things are looking up, assuming I can make it fit, and fit snugly.

I need to find out if the super duty inner seals will work for this axle. If not, I'm sure I can come up with something.

still need access to a lathe....

Well I am posting this out of state, at work. I should be home tommorrow night, so hopefully I will be back at it on thursday!

Last edited by camccardell; January 19th, 2010 at 06:41 PM.
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Old January 19th, 2010, 07:21 PM   #39
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cut off most of the tube, figure out method of removing plug welds, cut a slit in the tube to remove the pressure and hammer out the piece of tube. heat center and give it a go with your press to install the new tube.
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Old January 19th, 2010, 08:54 PM   #40
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Quote:
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cut off most of the tube, figure out method of removing plug welds, cut a slit in the tube to remove the pressure and hammer out the piece of tube. heat center and give it a go with your press to install the new tube.
My thoughts exactly. Would be cool to see this done
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