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am I f***ed Dana 60 ?



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Old 09-18-2012, 09:30 PM   #1
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am I f***ed Dana 60 ?

Dana 60 front Chevy or dodge not sure. But I broke both bolts that hold the passenger spring plate to the housing. I tried drilling for a ezout but broek the dam drill bit in both bolts. any advice on how to remove the broken bolts?
Pic will come later as I am just really pissed off right now!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!
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Old 09-18-2012, 09:34 PM   #2
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No, you are fine - get a u-bolt. I did mine quite a
Few years ago. 4.5x11x5/8 off the top of my head. Search, spring perch on here.



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Old 09-18-2012, 09:35 PM   #3
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Sounds like its time to link it.
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Old 09-18-2012, 09:41 PM   #4
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Weld something to the bolts to get em out, or just do 90k5s method. If its a dodge though gonna be a little tougher.

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Old 09-18-2012, 10:08 PM   #5
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I'd do 90k5s method. You have 4 weeks
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Old 09-18-2012, 10:10 PM   #6
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sorry didn't think to search first. I feel better now that i see the options.
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Old 09-18-2012, 10:13 PM   #7
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U bolt won't work if it's a dodge axle.
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Old 09-18-2012, 10:18 PM   #8
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U bolt won't work if it's a dodge axle.
Its been done from my searches.

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Old 09-18-2012, 10:25 PM   #9
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I second welding a nut to the stud has worked many times for me.
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Old 09-18-2012, 10:30 PM   #10
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Take a chisel and try and turn the bits backwards a little to break them loose then fish out. When u break one it's time to stop and rethink ur method of drilling, not move on to the next.

It's a sore spot with me cause guys do that **** at work, break bits, taps and ease outs then ask for help.
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Old 09-18-2012, 11:23 PM   #11
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Its been done from my searches.

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post up some info then. I dont see how it can be done in a way that makes sense. The studs are in line with the diff cover bolts, which would mean you would have to have a u bolt that blocked the diff cover bolts, not worth the hassle IMO to have to pull a u bolt to change diff oil..

Found 1 guy on pirate that did it on a dodge 60, and sure enough he is blocking the diff cover bolts, seems like a pain in the @$$ to me, but to each their own..
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Old 09-19-2012, 12:03 AM   #12
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Yeah that's what i saw and yeah thats what happens. How many times do you change your gear oil? I bet extracting studs sucks way worse. However yeah probably not worth grinding down the cover bolts etc

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Old 09-19-2012, 01:37 AM   #13
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Sounds like its time to link it.
This^^^^^^

I broke one of mine off on my old jeep and linked the front. Very easy fix.....
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Old 09-19-2012, 11:23 AM   #14
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If you can/want,
Take a 1/4 hilti bit and a hammer drill, and drill the hilti bit into the broken drill bit.
We have used this a few times. It will shatter the drill bit into pieces. Make sure if you try this to where a face shield.
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Old 09-19-2012, 11:26 AM   #15
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If you can/want,
Take a 1/4 hilti bit and a hammer drill, and drill the hilti bit into the broken drill bit.
We have used this a few times. It will shatter the drill bit into pieces. Make sure if you try this to where a face shield.
This works, also wear a welding jacket. A chunk of bit or tap breaking will embed itself into your stomach and or arm through a heavy shirt.
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Old 09-19-2012, 11:29 AM   #16
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If you can/want,
Take a 1/4 hilti bit and a hammer drill, and drill the hilti bit into the broken drill bit.
We have used this a few times. It will shatter the drill bit into pieces. Make sure if you try this to where a face shield.
Didn't think about that, that would work. I have used punches and chisels, this would be much easier.
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Old 09-19-2012, 08:06 PM   #17
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Well after looking today I have the dodge 60 front. I am going to try tommorrow the weld on bolt method. I don't have the time to link it right now. I will let you guys know how it goes
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Old 09-19-2012, 08:32 PM   #18
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Bob, spray the studs with some good penetrating oil (kroil, pb blaster, or even put a lil ATF on em), weld the nuts on fairly hot and allow them to fully cool, after that they should back out.
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Old 09-19-2012, 08:38 PM   #19
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gonna try that tommorrow
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Old 09-20-2012, 10:19 AM   #20
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I am going to agree on the welding nut method. I would clean it all well and weld it as hot as you can since you only get one chance to stick it hard. I also agree with letting it cool completely before doing anything. I would work at it with an impact when you start trying to back it out and start by going in, not out. Work it both directions on a lower torque setting and it should pop loose. Impact always helps on stuff that is stuck.
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Old 09-20-2012, 01:17 PM   #21
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Can't remember who on here told me to do this but it worked great. Weld a nut to it then while it's still super hot spray it down with WD or something similar and the steam will get between the threads and she will come right out.
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