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It appears to be uber easy, as all you do is pop the tops and re-install, but in reality, can turn into an absolute nightmare of a job. The TM covers it really well, and there's a pirate link to a full D60 rebuild.
And just an FYI, the driver's side kingpin cap is, shall we say, challenging to get off the studs. Also, when putting them back on, a couple of C clamps come in really handy.
Kingpin springs and bushing and a new steering stabilizer cured my death wobble. Same exact symptoms as yours.
Dana 60 Kingpin Springs and Bushings Kits from Offroad Design 4x4 Parts
Curious what was holding your hub on. Got a bunch of lighting projects for my camper. Other than that, I need some shocks, door rubber, and I think I'm good to go for the winter.
Just did this after I had no lights coming home from hunting last night. I cursed myself because the new switch in its parts box was sitting on the passenger seat. Like said above, very straightforward, except getting that 8mm screw back on was tricky. It's tiny and in a hard to reach spot...
I'm running these on my 1028 as well with no lift and a little trimming. I did have to put a slightly longer steering stop screw on the drivers side to prevent rubbing the pitman arm tie rod end.
OK, work with me here. I think I figured out my problem, thanks to extensive searching on the old site.
What I did was what I thought I was doing which was to "tap into the light blue wire" on the harness and wire to a momentary ON switch, the other side of switch to ground.
I did that. What...
Is your voltmeter dipping on start up and returning to green? Also, have you tried to bypass the controller and manually fire the plugs?
One last thing, where are you located? I was born and raised in that region.
Look at pg. 161 of the 31P (fig. 67).
Also it seems to be the dark blue wire...
But how would it have stayed on after original install without the allens, unless someone just decided to take them off way down the road?
Either way, shouldn't be hard to get it off, especially compared to some other things on the truck (e.g. everything around the kingpins).