looking at the ratech 10009 dana 60 pinion depth tool,im starting from scratch so i have no old shims to go off,the pinion is marked +1.i will be using the splash piece under the pinion bearing and the baffle with a shim under the race cup in the housing.rear is a dana 60hd housing installing 4.10 factory gears.thanks for any info.

I used one when I set up my used 4.56 gear set. Actually checked my 4.30 gears before I removed them and it was within .0002 of where they were installed. A newer gear set with the depth inscribed on it makes the install much easier with that particular tool as you can see with their instructions:

http://www.ratechmfg.com/pinion%20setting%20tool.htm

ok sounds good,i will get the tool.im just looking for something to get a reference to start with,to get me in the ball park,i have no old shims to start with .rear housing is a dana hd60.thanks mike

If you have no shims it will take a few tries to get the pinion depth right. Aftermarket gearsets have the pinion depth marked on them, for example 3.127, which would be +.002 (or .002 less shims) from the designed ideal depth of 3.125. Since you have none, a good starting point on shims is .035"

Do yourself a huge favor and make or buy some setup bearings before you start the build
I use setup bearings on just about every rear I do now except 9" rears,somebody was thinking about the technician whey designed that carrier.
Gus

well mine is a S60 so it's like hitting the easy button compared to a regular D60 Side adjusters for the win!

I also prefer to put the shim under the bearing race for ease of making changes.

yes im using going to be using the set up bearings.thanks for the info.i have a baffle .020 +.025 in shims under the bearing race=.045 and the splash shield between the pinion head and rear pinion bearing is .030.to start with.

Dont want to hijack the thread but the baffle and splash shields that come with the bearing shim kits, where do they go and do they need to be installed?? My D60 was out of an F250 rear and didnt have any of them installed, just the shim packs under the bearings per normal