Dana 30 Rebuild Guide Pt.1: K Suspension Axle Truss, IRO Axle Sleeve, Cut n' Turn (FIX YOUR CASTER!) 

The reference angle from the face of the diff cover is irrelevant. As long as your initial markings are at the stock position, you could have just zeroed the angle finder on the Inner C and rotate from there.

29:21 did you just try to blow the flame out 🤣

Got to be a lot of work cut and weld the C ‘s yet you don’t have to worry about the drive shaft angles to transfer case. Set your camber only once. Buy longer saw all blades will help. Preheat both pcs with a good rosebud, torch set up get about 450 degrees, weld it and wrap up the weld area with a asbestos blanket it’s not the same kind of asbestos. Where you have to worry about any fibers getting into your lungs. Slow cool down is the best welding cast steel. If it’s cast iron use a high nickel compound welding wire or a stainless steel wire using argon gas. Other wise you can get weld rejection, cracks, holes within the weld.

Should have pulled the ball joints and measured from the ball joint bores and you could have had reliable measurements.

Very informative video, love how your dog made himself right at home in front of the camera! LOL

Wow, awesome video mate, I was thinking about doing something like this myself but never thought about cutting the C's off. I was thinking about drilling away the spot welds that hold the tubes in place (if there are any welds at all) and pressing the tubes out of the pumpkin, rotate them and press them back in again and weld along the sleeve of the pumpkin so I keep the C's untouched.

Thank you for the thorough video. Put my mind at ease about tackling my axle build.

Ok your not wrong but for the amount of lift you way over did this. Good job but again a little bit for these mods

Great video man. The quality all around is awesome👍🏻

0:20 good boye! Perfect opening shot

good video man especially on the cut and turn

A Awesome Tutorial, Thanks 🙏

How do you like that cav fab steering? And death wobble

Is this a hp Dana 30? Will work with low pinion?

I know it's a three year old video, but I have to point out some errors. The axle is suspended by parallel links. So as the suspension extends the pinion does not stay pointed at the transfer case. It drops vertically and keeps the same pinion angle relative to the frame. Vibration is caused by a disparity in the angle correction given by the U joints at each end of the driveshaft. 'Aiming' the pinion at the transfer case causes the problem. Lowering the transfer case will help with driveshaft deflection angles. The rotation caused by lift kits is due to engineering mistakes in the less expensive kits. It can be corrected with adjustable links. When the lift goes beyond 4" it is time to go to long arms. Not because of pinion angle, rather to keep the front axle from swinging back towards the middle of the vehicle.

Great Video!

Why did you not just cut the welds? And not cut the axle tube all the way threw

Love this video!! This is my plan with mine!

Harmonic balancer puller works great for removing pinion yokes. Might have to buy longer bolts with the same thread as your pinion yoke. Before I had the right too to hold the pinion yoke for reinstallation,I used a really old large pipe wrench that I picked up at a garage sale about 25 years ago. It is about 3 feet long, and it's bent. Every time I use it, I can't help but wonder how the heck it got bent. It's gotta be the oldest tool I own. Maybe it got run over by a 🚂

Thank You for all your hard work putting this great video together..

What welder did you use? Can I do this with my miller 135 mig welder?

could you comment about the way the steering feels with proper caster versus not enough. thanks .

Did I catch you are also doing the WJ knuckles and big brakes. Martin built also went with 1 ton over axle steering…is that compatible with this process? I will echo the previous comment awesome video!

Well? How have the welds held up? Been considering this for my TJ

Great video but why wouldn’t you upgrade to a Dana 44 or bigger?

I might of missed it, but what type and size is your lift?

Wow bro, your the best

The real star is the pup 🙂

Just wondering? Just rotating the knuckle, doesn't that throw off your spring perch angle?

Excellent video bro!

Please show how you did the hidden winch on the stock bumper!!

Seems like this method would really weaken the axle at the weld point. Is that why you put the axle sleeves in?

Is a stock Dana 30 axle (not trussed, sleeves, no HD ball joints) strong enough to run 35’s and be able to wheel moderately?