1997 Jeep Wrangler TJ - Custom Dana 60 Axle Install

Project Teal-J II, Intro
Project Teal-J II, Part 1
Project Teal-J II, Part 2
Project Teal-J II, Part 3
Project Teal-J II, Part 4
Project Teal-J II, Part 5
Project Teal-J II, Part 6
Project Teal-J II, Part 7
Project Teal-J II, Part 8
Project Teal-J II, Part 9
Project Teal-J II, Part 10
Project Teal-J II, Part 11
Project Teal-J II, Part 12
Project Teal-J II, Part 13
Project Teal-J II, Part 14

For those of you who read last month's installment, you're probably looking for Part 2 of the Hemi V-8 swap. Before we address that, however, we thought it was a good time to address the common issue of properly matching drivetrain components to engine output.

In our case, Teal-J will have more than 370 lb-ft of torque on tap, which would likely make scrap metal of the Jeep's locked Dana 44 rear axle. So we began looking at different axle options. Specifically, we wanted to find the correct rearend for the type of driving we intend to do with the Jeep - mainly rockcrawling trails, the pavement leading to them, and the occasional sand dune. Besides being able to handle the increased torque loads, the things we wanted in our new axle were high ground clearance, readily available internals, and a reputation of trouble-free service. We considered a couple of other companies that built Dana 60s in smaller quantities, but felt most confident with the largely successful bolt-in replacement Pro-Rock 60 from Dynatrac of Huntington Beach, California, which builds these highly sought-after axles for some of the biggest names in professional rock racing. Legends such as Walker Evans, Ken Shoop, and John Gilliand all rely on Dynatrac's superior quality and attention to detail for their competition axle needs. So follow along as we reveal some of the tricks that make a Pro-Rock 60 superior in strength and reliability.

1.) Dynatrac fit our Pro-Rock axle with a Detroit Locker to ensure trouble-free traction. Also, a new set of 4.56:1 Yukon Gears was supplied by Randy's Ring & Pinion to match the front axle. Because of its high-pinion design, a Pro-Rock housing requires reverse-cut gears.

2.) These oil galleys are engineered into the Pro-Rock design to allow proper lubrication of the pinion bearings (arrows).

3.) This photo illustrates the difference between Dana 44 and Dana 60 axleshafts. This increase in girth should stand up to the torque of the new Hemi engine.
3.) This photo illustrates the difference between Dana 44 and Dana 60 axleshafts. This inc
4.) With the completed tubes pressed into the housing, the axle was set into a jig for bracket positioning. Dynatrac always uses brand-new brackets with exactly the same dimensions as the factory parts. This way, the axle will bolt right in. Besides offering bolt-in replacements, Dynatrac can custom-make axles for your specific application.
4.) With the completed tubes pressed into the housing, the axle was set into a jig for bra
5.) First, each bracket was bolted to a fixture that positioned it on the axlehousing. Shortly after, each bracket was tack-welded in place.
5.) First, each bracket was bolted to a fixture that positioned it on the axlehousing. Sho

6.) Once all brackets were in place, some critical measurements were taken to ensure proper alignment. Next, each bracket was finish-welded to the housing. Careful attention was given not to overheat any one area of the housing. When everything was attached, a coat of paint was applied. Finally, the bearings, seals, gears, locker, and 35-spline axleshafts were installed.