The Escalation Of General Maintenance

Turn on subtitles or view the transcript at the bottom of the description if you'd like explanations on what I'm doing throughout the video

Last week I replaced the TTB Dana 44 that came in this truck with a straight axle Dana 60 (   • F250, Dana 60  ). The used axle came out of a very beat up plow-truck F350, I thought I could get by without replacing all the wear parts. I ended up replacing the u joints, brake components, a wheel bearing, and more. I did not replace the axle seals, and the passenger side leaks profusely. I took everything apart to replace the seal and I also installed a locking differential. After putting it back to together, it still leaks. It turns out that the passenger side axle tube is significantly bent and partially pulled out of the housing. I failed to recognize some the signs that pointed to it, like having to pry the leaf springs apart to bolt them in, or having to hammer the axle in and all the resistance to turn the pinion. I was very doubtful but without being able to source a replacement quickly, I was able to bend the 1 ton axle back into place. It's not perfect, but everything seals and turns freely.

Chapters:
00:00 - Disassembly to replace leaking axle seals
04:35 - Replacing pinion seal
09:18 - Removing the axle seals
11:43 - Installing a LockRight locking differential
16:13 - Installing the new axle seals
17:33 - Putting everything back together
25:18 - It still leaks
27:07 - Repair sleeve on the axle
28:24 - It still leaks
30:02 - The axle is bent
31:46 - Unbending the axle, attempt 1
34:37 - Removing the axle housing
38:33 - Unbending the axle, attempt 2 (worked)
47:08 - Reinforcing the axle housing
53:59 - Final reassembly
1:04:55 - Testing my locking differential
1:08:40 - Cat