Will a Dana 60 master setup kit

[Jode]

fit a 1996 Sals rear? I've been trying to find an answer to this by reviewing earlier threads but so far no luck, as I'm planning a rebuild for the rear diff on our TDI.

[LowRanger]

Not really too sure what exactly you want to replace.But I have a Dana 60 ring and pinion fitted in my Salisbury,and used a Dana 6 install kit,just needing to replace the bolts for the ring gear,as the Salisbury is metric.When I changed the pinion,I also fitted a custom pinion flange to allow direct fitment of the original driveshaft.

[goingbush]

yes, assuming a d60 setup kit is just a set of carrier bearings that have had the cones honed out, so that you can add shim pack and push on on the carrier bearings (by hand) , fit carrier to test for backlash & preload, then remove carrier, and easily remove bearings to adjust shims if necessary.

probably easier to buy a second set of carrier cones locally & hone them out.
once you have sussed out the correct shim pack, pull carrier again and fit new cones.

no need for the big shims that come with D60 setup kit , (the ones between cups & housing) they are not applicable on 8HA sals.

[Jode]

Thanks, Low Ranger. The plan is to fit a TruTrac plus new bearings, so I will need to reset carrier bearing pre-load, and will likely need to fiddle with gear mesh patterns, although I'll start off with the same shims as the current set-up and hope that they give the requisite mesh pattern. Thanks for highlighting that the crown wheel bolts on the Sals are metric and the Dana imperial - those impreial bolts wouldn't be much use for this task.

Wizard, I would need the shim pack for the carrier bearing pre-load; and I presume the big shims that you refer to are those used for the Dana pinion - the Sals uses shims behind the pinion-gear end of the pinion itself to control pinion/crown wheel mesh IIRC. So will MOST of the shims in the Dana kit fit the Sals (carrier bearing shims only)? It would be handy to buy a kit that has ALL of the bearings (2 carrier, 2 pinion) plus ALL necessary shims (being a range of thicknesses to allow adjustment).