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So I bought a Dana Super 60 High pinion Front center casting to experiment with test fitting in the Bronco. After much research and measuring, I decided I needed a case with the angled cover ( to clear the steering rack) , similar to Currie and Terraflex. Neither of those guys would sell there empty center section, they only sell them in complete axle assemblies for big money. After trying about 12 different companies I finally came across East Coast gear supply and they agreed to sell me their empty cast nodular Steel center section.
It finally arrived today and I began the process of hacking off the webbing and ribs that are unnecessary and the extra width of the round casting where the tubes are inserted wasn't needed either.
After bench-pressing the unit in place no less than 15Xs, marking and measuring, and then cutting and grinding.
Even after all the modifications to the case, I still needed to notch the crossmember 3/8"...
The diff cover is 1/2" thick and also required modifications.
It's not even close to being finished, however IT DOES FIT!
Obviously, I'll be ordering ring and pinion and E-Locker and seals and bearings soon for it.
In the meantime I'll drop off the case and the intermediate shaft tube at the machine shop and have it centered and boared and tapped so it will bolt on. The spicer part Im using is off the Extreem FDU and the shaft itself is 1.5" (35 spline sized) and the ends are necked down to 32 splines as Spicer offers it, This allows me to use the Spicer tube and then just use a 1.5" 35 spline upgraded intermediate shaft. Even the little bearing in the end of the intermediate tube is the RIGHT size 1.5"!
The Actual CV stub axles flange will be 935 flanges.
Here's pics.
It finally arrived today and I began the process of hacking off the webbing and ribs that are unnecessary and the extra width of the round casting where the tubes are inserted wasn't needed either.
After bench-pressing the unit in place no less than 15Xs, marking and measuring, and then cutting and grinding.
Even after all the modifications to the case, I still needed to notch the crossmember 3/8"...
The diff cover is 1/2" thick and also required modifications.
It's not even close to being finished, however IT DOES FIT!
Obviously, I'll be ordering ring and pinion and E-Locker and seals and bearings soon for it.
In the meantime I'll drop off the case and the intermediate shaft tube at the machine shop and have it centered and boared and tapped so it will bolt on. The spicer part Im using is off the Extreem FDU and the shaft itself is 1.5" (35 spline sized) and the ends are necked down to 32 splines as Spicer offers it, This allows me to use the Spicer tube and then just use a 1.5" 35 spline upgraded intermediate shaft. Even the little bearing in the end of the intermediate tube is the RIGHT size 1.5"!
The Actual CV stub axles flange will be 935 flanges.
Here's pics.
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