Synergy 4105 / 6 - D60 Drive Gears - Manual

SYNERGY MFG. 870 INDUSTRIAL WAY, SAN LUIS OBISPO, CA (805) 242-0397
PPM-4105 Dana 60 Drive Flange Kit
General Notes:
Our kits are CNC machined from 4140 chromoly and heat treated for maximum strength.
Replaces existing 30 & 35 spline locking hub or drive gear assembly.
For use on Dana 60 front or rear steer assemblies.
Packing List:
(2) Drive gear cover plates
(2) 4140 thru hardened drive gears
(2) Large snap rings
(2) Large square rings
(8) Small o-rings
(8) Stainless steel socket head cap screws
(8) Stainless steel washers
(2) Spacers plates
(1) Locitite
(2) Small snap-rings
Instructions:
1. Remove the existing hub or drive gear assembly & clean the internal drive splines.
2. Apply a small coat of axle grease to the inside splined area of the hub.
3. Insert the drive gear. Install the drive gear with the bolt holes facing out.
4. Install the small snap ring on the end of the stub axle
5. Install the spacer plate; align the notches in the spacer plate with the threaded holes in
the drive gear. The bolts go through the spacer plate and thread into the drive gear. If
you need to remove the drive gears and still use the cap, you can screw the bolts into
the threaded holes of the spacer plate.
6. Install the internal snap ring to retain the drive gear and spacer plate in the hub.
7. Install the washers then the small o-rings onto the stainless steel socket head cap
screws, put a small amount of grease on the o-ring so they do not get pinched and cut.
8. Apply the large o-ring in the machined groove on the inside of the cover plate.
9. Position the cover plate so that the 4 holes are lined up correctly.
10. Apply a small amount of Loctite to each stainless steel socket head cap screw which
retains the cover plate.