Bastard D60 Disc Swap Help

Mountain Ram

Well-Known Member
Joined
Nov 15, 2005
Location
VA
I have all the mid-late 70s chevy K20 front end stuff to do a disc swap on my '95 Dodge rear D60. I have done this before on other D60s and it should be straight forward. Except of course- the studs for the chevy aren't big enough at the knurl for my '95 rear wheel hub.

After searching extensively- it appears the studs in my '95 are actually for the HD 9.25 rear axle and have a .666 dia knurl (I think this is a sign) and almost everything else uses a .620 or .625 knurl dia (chevy is .625). Obviously I have a Bastard axle!! I have gone thru every wheel stud manufacturer possible and can't find a stud that will work. If the studs aren't a press fit at the knurl- the lugs will never get torqued...

Moving on to the rear wheel hub- I know this is a D60- I have been around long enough to know the difference. I looked at the bearing numbers and they are for the D60. I believe if I can find a pair of '94-'98 Dodge D60 wheel hubs, I should be good to go. Of course- it appears that these aren't available from the standard parts stores...

At this point- I am open to anything- I just want to get the brakes on and get this thing rolling again...

TD
 
weld the studs in?
 
Thought about that but worreid about welding to cast as well as heating the rotors...

Anyway- I think I got it worked out... this turned out to be a Major PITA- I had to hit every parts store in town at least once!

In case anyone ever needs to know-

My D60 rear came from a '95 Dodge 2500 4x4 with the 360 V8. The disc brakes mount to the back of the hub. The common swap for the D60 includes all the parts from the 73-91 Chevy 3/4 ton, but not this axle.

I got the brackets from Shawn at Great Lakes Offroad. I had to get rotors from a '93 Ford F250 4x4 with the 7.4L (Found on pavementsucks.com). The chevy rotors were not deep enough.

My axle calls for studs with a .625 knurl, but my trusty dial caliper showed that my factory pieces had a .648 knurl. The Chevy pieces come with .625. The hole in the Ford rotors is about .655, so I had to find studs to work. Someon on Pirate recommended Dorman 610-389 and those worked out well. The studs have a .666 knurl that press into the rotor and the shoulder is a very tight fit in the hub. Probably not ideal, but I think it will work.

I also got loaded calipers for the Chevy and these bolted right up and were spaced correctly for the Ford rotor.

TD
 
Yep- best $250 I ever spent!! I have been scaring the neighbors now by driving it around the neighborhood!! I have only gravity bled the rears, but they work well.

I took out the prop valve altogether- I think it may have been a problem for a long time. The leaky rear axle seal and gear oil soaked brakes probably didn't help much.

You gonna try to make the Toy Ride in Callalantee?
 
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