Last month we showed you how Currie Enterprises assembled our Iron Jock 60 front axle housing for the front of our SuperBurb project rig. This month, we delve into the remainder of the project and show you how all the individual parts and pieces came together during assembly. Check it out. Picking up where we left off, the new Iron Jock 60 housing was ready and waiting for knuckle assembly and installation of internals such as the differential and axleshafts. Here you can see the Currie technician measuring the housing to determine axleshaft length.Picking up where we left off, the new Iron Jock 60 housing was ready and waiting for knuck All Currie axleshafts start out as a raw forging of 4340 chrome-moly material as shown here. Each shaft is cut to length on a chop saw, then each is placed in a special grinding tool that machines the final outside diameter of all bearing and seal surfaces.All Currie axleshafts start out as a raw forging of 4340 chrome-moly material as shown her Once an axleshaft leaves the grinding machine, Currie's splining technician readies the shafts for the spline-cutting tool. Our shafts were spec'ed out as 35-spline; however, the same computer-controlled machine can cut any spline count a customer needs, and with a simple calibration change, the tool can be reconfigured to cut virtually any spline count. The spline cutter utilizes a spinning tool bit with a series of special cutting blades that create the proper pressure angles necessary for a particular spline design. As each spline is cut, the machine rotates the shaft to position the cutting head for the next pass.Once an axleshaft leaves the grinding machine, Currie's splining technician readies the sh Randy's Ring & Pinion supplied us with a 4.88:1 gearset to match the rearend of our Suburban. We love working with Randy's because they always seem to have the right part in stock when we need it, and thanks to a healthy distribution system, they can typically get the parts to us the very next day.Randy's Ring & Pinion supplied us with a 4.88:1 gearset to match the rearend of our Suburb Eaton sent us a trail-proven Detroit Locker to use for this project. We picked this differential because they rarely, if ever, fail. The design utilizes robust internal parts to ensure that 100-percent traction is delivered to both drive wheels whenever torque is applied. The Detroit Locker automatically allows wheelspeed differentiation when needed. This enables the inside wheel to track around a corner at a slower speed than the wheel on the outside of the corner.Eaton sent us a trail-proven Detroit Locker to use for this project. We picked this differ Once the ring and pinion parts were installed along with the Detroit Locker, the Currie technician set up a gear pattern to spread drive torque out evenly over the middle of the teeth. This pattern will contribute to long wear life and noise-free operation.Once the ring and pinion parts were installed along with the Detroit Locker, the Currie te One of the things that sets the Currie Iron Jock axle assembly apart from other aftermarket Dana 60 designs is the use of a larger front pinion support bearing. The bearing on the right is the size used for both the front and rear pinion support bearings, whereas the bearing on the left is the size commonly used in the front of virtually all stock and aftermarket Dana 60 housings.One of the things that sets the Currie Iron Jock axle assembly apart from other aftermarke Currie utilizes this machined bearing spacer to enable the smaller front end of the pinion to fit properly with the larger bearing mentioned above.Currie utilizes this machined bearing spacer to enable the smaller front end of the pinion Here you can see the front pinion bearing prior to the installation of the pinion seal. Notice the oil channel (arrow) that feeds gear oil to the front side of this bearing. When operating, oil is pumped up to the front side of this bearing by the ring gear. With this design, oil must flow through though each of the pinion support bearings to complete the lubrication circuit.Here you can see the front pinion bearing prior to the installation of the pinion seal. No We secured a pair of Yukon's Dana 60 Super Joints to further strengthen our front drive system. These U-joints were machined from a solid chunk of through-hardened 4340 steel and then treated with a titanium nitrate coating (the gold color), giving it super-high-wear characteristics. This allows the cross to ride directly in the induction-hardened 4140-chrome-moly caps with very tight clearances and without a separate bushing or needle bearings. Lacking separate cap bushings or needle bearings, the trunnion is larger in diameter as well, adding to overall strength. The trunnion on the Super Joint is some five percent larger than a traditional Dana 60 U-joint (0.935 versus 0.892 inch). A special 200,000psi compressive strength copper-based grease is included with the pair, along with a compact and very handy grease gun. Yukon says that this is the only grease you should use with the Super Joint.We secured a pair of Yukon's Dana 60 Super Joints to further strengthen our front drive sy Randy's Ring & Pinion also set us up with a pair of 35-spline 4340 steel stub axles for this project. These shafts provide an excellent value in terms of strength per dollar spent. Sure, we could have sourced ultimate-strength 300M stub axles, but for our needs, 4340 should survive just fine.Randy's Ring & Pinion also set us up with a pair of 35-spline 4340 steel stub axles for th Our friends at Boyce Equipment sent us an assortment of parts needed to complete the buildup. These Chevy-style Dana 60 spindles, along with all the necessary bearings and locking spindle nuts, made the process of final assembly a snap.Our friends at Boyce Equipment sent us an assortment of parts needed to complete the build In addition to the front spindles and bearing parts, Boyce Equipment supplied us with Chevy eight-lug brake rotors preassembled with hubs and lug studs as shown here. Boyce offers these parts directly through their website or by phone. In most cases, the parts are regularly stocked and ready to ship anywhere in the country as needed.In addition to the front spindles and bearing parts, Boyce Equipment supplied us with Chev Randy's Ring & Pinion supplied us with two Chevy kingpin rebuild kits for our Reid Racing knuckles. These roller bearings are what carry the entire weight of the front of the truck. We like this design better than the new-style ball joints use by OEMs because these are rebuildable and offer significant gains in strength.Randy's Ring & Pinion supplied us with two Chevy kingpin rebuild kits for our Reid Racing The only parts we forgot to order from Randy's were these Spicer lower kingpin caps. A quick call to Parts Mike, a leading supplier of axle-related parts and equipment, was all it took to get the overlooked parts and ensure that we could finish up the photo shoot on the following day.The only parts we forgot to order from Randy's were these Spicer lower kingpin caps. A qui With the knuckles, spindles and caliper brackets mounted in place, the Currie technician installed the new disc brake rotors and bearings to the assembly.With the knuckles, spindles and caliper brackets mounted in place, the Currie technician i Boyce Equipment also supplied us with all the remaining front brake parts we needed to complete the build. These off-the-shelf Dana 60 calipers are typically found on '75 Chevy 1-ton pickups. In addition to the individual axle parts Boyce supplied to us for this project, Boyce offers complete Dana 44, 60, 70, and 80 assemblies ready to fit under your full-size pickup or SUV.Boyce Equipment also supplied us with all the remaining front brake parts we needed to com We sourced a pair of 35-spline Warn premium locking hubs to finish off the buildup. This is the sacrificial differential skidplate that Currie installs to the bottom side of each and every Rock Jock and Iron Jock 60 axle they build. These skidplates are made from abrasion-resistant AR400 steel material-the same material used on bulldozer blades and backhoe buckets. The idea is that this bolt-on skid will take the abuse so that the cast-iron center section does not have to. We like that they can easily be replaced as needed by simply removing four Allen bolts.This is the sacrificial differential skidplate that Currie installs to the bottom side of This is the standard stamped-steel differential cover Currie includes with all Iron Jock 60 axles. Also available as an upgrade option, Currie offers a thick version of this cover, which allows additional weld surface for custom fabrication of link mounts and/or hydraulic ram setups.This is the standard stamped-steel differential cover Currie includes with all Iron Jock 6 SOURCES Currie Enterprises 382 North Smith Corona CA 92880 714-528-6957 www.currieenterprises.com Boyce Equipment 2893 So. American Way Ogden UT 84401 800-748-4269 www.boyceequipment.com Eaton 1111 Superior Avenue Cleveland OH 44114 800-328-3850 www.detroitlocker.com Parts Mike N/A AK 530-885-3850 www.partsmike.com Randy's Ring & Pinion (Yukon Gear) 10411 Airport Road SE Everett WA 98204 866-631-0196 www.ringpinion.com Warn Industries 12900 S.E. Capps Road Clackamas OR 97015 800-910-1122 www.warn.com Reid Racing 1917 Oak Park Blvd. Pleasant Hill CA 94523 925-935-3025 http://www.reidracing.biz/ By Robin Stover Enjoyed this Post? Subscribe to our RSS Feed, or use your favorite social media to recommend us to friends and colleagues!