Dana 60 Bible

Pirate4x4.Com - Extreme Four Wheel Drive Page 1 of 23 Front Dana 60 Axle Tech (Page 1) (Click on most pics for a larger version) Last updated: Monday, April 21, 2003 02:06 AM . Changes since last update indicated in yellow text. [Page 1] [Page2] Intro: This article is intended to collect together technical info and practical hands-on data about the venerable Dana 60 front axle. It is not a how-to article, but more a collection of information and facts. With an article of this scope, it is very difficult to personally verify all the information or ensure complete accuracy, but I have attempted to be as complete and accurate as possible. Keep in mind that nothing in the axle world is cast in stone, variations are always possible. Disclaimer: I do not recommend nor endorse any of the modifications shown in this article, the information is provided for personal information purposes only. I am not an Engineer, metallurgist, or mechanic - I have absolutely no professional qualifications whatsoever in this regard - I have simply collected information from others. Use of any of the information contained herein is at your own risk. It is therefore your responsibility to maintain safety in and around your vehicle at all times. It is likely that some procedures featured here may void your vehicle's (or parts thereof) warranty. It is also likely that some of the information featured shows procedures that may not be legal for street use in some or all states within the US and/or any other countries and may not be safe for on or off-road use. The article's author, nor anyone related to this web page, cannot be held responsible for any damage, failure, or violations of the law, that might result from from the use of any information contained on this page, or linked to on this page . In particular I do not recommend the grinding of brake callipers, nor the conversion of dual rear wheel (DRW) hubs to single rear wheel (SRW) hubs, as these components were never designed to be modified and used in this manner. Acknowledgements: There is no way all this information could have been compiled without the help of a great number of people - some knowingly, most not. I harvested the information from about 1999-2002 mostly from the most excellent Pirate4x4.Com Bulletin Board, but also from other knowledgeable wheelers, manufacturer's web sites, and the personal experience of my club mates and I. If you notice any errors, please let me know via our club bulletin board The Right Coast Crawlers BB. If you notice pictures or large portions of text that are yours and you would like specific credit, let me know. Also, if I have used pictures of yours that you object to, please let me know so that I can remove them. With that said, I must give thanks to the following list of folks, although the list is by no means complete: Sherpa rig, Patooyee, 66CJDean, Wolf 359, Onetonwillysands10, Scott at Rockstomper, Emsoffroad, Alpo, Ant, Aggro, BadDog, BigDude, PinBall, Ultim8kaos, Chad. Extra special thanks to Steve Gerstner of Differential Engineering for taking the time to call me personally, all the way from Florida, to correct many of my mistakes and to share a little of his vast knowledge. Steve is one of, if not the, premier custom axle builder in North America. He has personally handled over 500 Dana60 front axles......now THAT's experience!! Attachments: The following documents located on our server provide additional information and data on the Front Dana 60 Dana Spicer light Axle service manual. Dana 60 Service Manual Links: The following companies and suppliers are sources of parts and info for the front Dana 60 CTM http://www.ctmracing.com/dana60.shtml Dutchman http://www.dutchmanms.com/ Dynatrac http://dynatrac.com/ Randy s http://www.ring-pinion.com/ Moser http://www.moserengineering.com/ Superior http://www.superioraxle.com/ Tera http://www.teraflx.com/ WMS http://www.wagonermachine.com/ Custom Differentials http://www.custom-differentials.com Boyce Equipment http://www.boyceequipment.com Shaker http://www.shakerbuilt.com Differential Engineering http://differentialeng.com/ Six States http://www.sixstates.com 4wd Factory http://www.4wdfactory.com/ Parts Mike http://www.partsmikeparts.com/60Front.htm JB s 4x4 http://www.jbs4x4.com./ Warn http://www.warn.com/ ORD http://www.offroaddesign.com/ Sunray http://www.sunrayengineering.com DTD http://www.drivetraindirect.com/ DTS http://www.drivetrainspecialists.com/ WCD http://www.differentials.com/ Reider racing http://www.reiderracing.com/ Rockstomper http://www.rockstomper.com/ Milemarker http://www.milemarker.com Superwinch http://www.superwinch.com The following are other great Front D60 tech articles: ORCs 35 spline stub shaft upgrade article http://www.off-road.com/chevy/tech/dana35spline/ ColoradoK5 article on installing a Boyce Equipment rebuilt Dana 60 http://www.coloradok5.com/boyce.shtml ColoradoK5 Dana 60 calliper grinding article http://www.coloradok5.com/d60calipergrind.shtml Alaska Offroad axle tech page http://www.alaskaoffroad.com/axle_tech.htm http://www.pirate4x4.com/tech/billavista/60_front/index.html 8/22/2007 Pirate4x4.Com - Extreme Four Wheel Drive Page 2 of 23 Off-road.com Dana 60 tech http://www.off-road.com/chevy/tech/dana60 Mike Knorr's Building an RC D60 http://www.bc4x4.com/tech/2001/hpd60front/ Wolf359's Dana 60 upgrade article http://www.gohumvee.com/images/Tech/60axleup/index.html Description: The Dana 60 front axle is a heavy-duty 4wd front steering axle manufactured by Dana Spicer corporation. It was most commonly used in many one ton and some 3/4 ton pickup trucks. Over the years there have been many different variations, from early Ford closed knuckle low pinion types, to the common GM kingpin low pinion, to the 94+ Dodge Dana 60 with a vacuum operated central axle disconnect, balljoints, and 32 spline inner shafts. The most desirable axles for heavy duty 4x4 use in stock form have open kingpin knuckles, 35 spline inner axles, 30 spline outer axles (stub shafts), and disc brakes. Later model Ford high pinion (HP) Dana 60s with balljoints instead of kingpins are also desirable axles, though many prefer the kingpin knuckles over the balljoints. The undesirable front Dana 60 axles will not be covered by this article, and include: 74-75.5 Ford low pinion drivers side closed knuckle drum brake with 30 spline inners, 19 spline outers, small ujoints and weak knuckles. 75.5-77 Ford low pinion drivers side open knuckle disc brake 30 spline inners, 19 spline outers, outer knuckle spindle pilot hole is smaller than 78+ axle and is therefore notched to allow 1480 series U-joint tp pass through. 94+ Dodge drivers side low pinion CAD unit bearing hub 32 spline 1.31 coil sprung Dana 60s Any other closed knuckle Dana 60, like those from a Jeep M715 that had coarse spline axles. Common applications for the desirable axles include: GM 1977-87 K30 1 ton 4wd 1984-88 CUCV 1988-91.5 V30 All GM / Chevy versions were passenger side differential, regular rotation (low pinion) gears, disc brakes, 35 spline inners, 30 spline outers, internal style hubs, and kingpin knuckles. Dodge 1975-89 D-600 1992-93 D-600 1981-89 D-700 1992-93 D-700 All these Dodge versions were passenger side differential, regular rotation (low pinion) gears, disc brakes, 35 spline inners, 30 spline outers, and kingpin knuckles. 1979-89 versions had external style hubs, with the earlier versions with full-time NP203 Transfer cases having external drive flanges, and later models having external lockout hubs. The external lockout hub bolt pattern is 8 x 3.960". The 90-93 versions had internal style hubs just like the Chevy and lockout hubs. One caution with dodge applications, is you have to be careful to avoid the Dana 61 front axle. 1987-88 and 1991-93.5 Dodge D600 and D700 also came with Dana 61. More info on the Dana 61 later in the article. Ford 1978-79 F-350 and some F-250 (Snofighter and High GVW packages) 1986-88 F-350 with dual rear wheels (DRW) 1988-91.5 F-350 with single rear wheels (SRW) 1992-95 F-350 (all) (balljoint) 1996.5-98 F-350 (all) (balljoint) 2000 F350/F450/F550 DRW (balljoint, metric 8x170mm wheel bolt pattern F350 / 8x220mm F450/F550, unit bearing hub) 2000.5 F350/F450/F550 DRW (balljoint, metric 8x170mm wheel bolt pattern F350 / 8x220mm F450/F550, unit bearing hub) 2001 F350 DRW (balljoint, metric 8x170mm wheel bolt pattern, unit bearing hub) 2001-02 F450/F550 DRW (balljoint, metric 8x220mm wheel bolt pattern, unit bearing hub) 2002 F250/F350 SRW (balljoint, metric 8x170mm wheel bolt pattern, unit bearing hub) 2002 F450/F550 DRW (balljoint, metric 8x220mm wheel bolt pattern, unit bearing hub) All these Ford versions were drivers side differential, reverse-cut (high pinion) gears, and kingpin knuckles to 1991.5 and balljoints thereafter. Most Ford D60s are internal style hubs, but external type lockout versions do exist. 2000 and later Ford D60s have balljoints, a metric wheel lug pattern of 8x170mm up to F350 and 8x220mm for F450/F550, different brakes and spindles, sealed "unit-bearing hubs", hub-centric wheels, different length axleshafts from the earlier D60s, and larger Superduty specific tie rod ends. From 2000 on, the Ford D60 front axle is also known as the Model 60F2000+ or the 248M. 248 just happens to be the equivalent in millimeters of 9.75" - the diameter of the D60s ring gear. IHC 1975 1300 camper Special 35 spline inner, 30 spline outer, external lockouts http://www.pirate4x4.com/tech/billavista/60_front/index.html 8/22/2007 Pirate4x4.Com - Extreme Four Wheel Drive Page 3 of 23 Differences between the front Dana 60s: This paragraph is just a quick summary of the most notable differences, more detailed info is spread throughout the article in the dimensions table, parts interchange table, etc. Dodge and Chevy front Dana 60s are very similar, and in many cases fairly interchangeable - both parts and entire assemblies. Differences do exist, and some are: 1) All Chevy D60s are kingpin knuckle, whereas early (79-93 ) Dodge are kingpin and later (94+ ) are balljoint (and undesirable) 2) All Chevy D60s are internal style lockout / drive flange bearing hubs, whereas early (79-89 ) Dodge are external, and later Dodge (90-93) are internal. 3) Dodge and Chevy outer kingpin knuckles are very similar, and either will bolt to the other axle, but they are not identical - tie-rod placement is different - the Dodge mounts the TRE about an inch and a half higher. Tie rod end taper is the same for all Chavy, Dodge up to 93, and 78-79 Ford. 85+ Ford is smaller to 99, then 2000+ Ford Superduty is larger and Super-duty sepcific. 4) Chevy leaf spring pads are 3 inches wide and 32 inches apart (center-pin to center-pin), Dodge are 2.5 inches wide and 32.5 inches apart. 5) All SRW Chevy D60s are 69" wide wheel-mounting-surface to wheel-mounting-surface (wms-wms). Most SRW Dodge are 67" wide, although some are reportedly 69" wide too. A Dodge DRW D60 is 75.5" wms-wms. 6) Chevy rotors are 1.5" thick, early dodge rotors are 1.25" thick, but the calipers are identical. Dodge D60s from the CTD years (90-ish to 93) have 1.5" rotors. 7) Dodge D60s from the CTD years (90-ish to 93) have a higher tierod location than the older Chevys. Differences between the Chevy/Dodge D60 and Ford D60 are more numerous and apparent. They include 1) Chevy/Dodge use a 6 bolt spindle mount pattern, Ford is 5 bolt 2) The Chevy/Dodge spindle and bearing/wheel hub are 5/8" longer than the Ford. 3) The Chevy/Dodge stub shaft is 0.600" longer than the Ford stub shaft 4) Chevy rotors are about 1.5" thick, the Ford and Dodge rotors are about 1.25" thick 5) Virtually all Ford front disc brakes used 2 piston calipers 6) The Chevy/Dodge outer knuckle is clearanced for their large single-piston calipers, the Ford are not. 7) The Chevy/Dodge caliper mounting bracket bolts on AFTER the spindle, as in knuckle-->spindle-->caliper bracket, whereas the Ford mounts the caliper bracket between the knuckle and spindle, as in knuckle-->caliper bracket-->spindle 8) The Chevy/Dodge are passenger drop regular cut low pinion diffs, the Ford are drivers drop reverse cut high pinion. 9) Chevy/Dodge uses six 1/2" spindle studs, Ford uses five 7/16" spindle studs 10) Ford knuckles seem to have more issues with the upper kingpin area strength than others. Chevy/Dodge knuckle has thicker ribbing around the upper kingpin area. 11) Ford knuckles have a shorter steering arm than the Chevy/Dodge. A 1.5" diameter tie-rod on a stock Ford D60 will justtouch the diff cover at full lock. The same tie-rod on a GM Dana 60 would be just over 1/2" away from the cover at full lock. Axle identification by BOM: Here is a table of front D60 axles showing Bill of Material (BOM) numbers, sorted by manufacturer. The BOM is stamped on the axle housing tube as indicated in the picture below. Unfortunately, they are not stamped very deeply, and in harsh winter climates are often illegible after many years. In some cases, the BOM is also stamped on the outer circumference of the ring gear. You can check the BOM of any 1979+ axle at Dana's site: http://www2.dana.com/expert/wc.dll?cvsp~Deabill~ Part of the Dana expert site at: http://www2.dana.com/expert/ Huge thanks for Patooyee for the information in the table. ** For a more thorough table of Front Dana 60 BOMs, including all the gear ratios, part numbers, etc. - Click HERE ** Table also includes Dana61 Front axle BOM's. Bill of Material Number Manufacturer 610430 DODGE 610604 DODGE 610540 DODGE 610539 DODGE 610532 DODGE 610518 DODGE 610135 DODGE Model Front / Rear 1992-92 1/2 D-600 & D-700 1996 W2500 HD 1995-95 1/2 W3500 1995-95 1/2 W2500 HD Application 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 1995-96 AIR FORCE TOW VEHICLE NON-ABS 1995-96 W2500 HD 1981-85 D-600 & D-700 http://www.pirate4x4.com/tech/billavista/60_front/index.html 8/22/2007 5" external 35 / 30 32.5" 2. and please send me corrections / info that you have. regular leaf 67.5" 69. pass. as well as info for filling in the blanks. and spring pad width are subject to error and variations. regular regular leaf leaf internal 35 / 30 internal 35 / 30 Dodge 79-91 D-600 & D700 D-600 & D- kingpin pass.5-78 K-30 1975 1300 Camper Special Stock Dana 60 front axle dimensions The wms.pirate4x4. Take with a grain of salt.html 8/22/2007 .5" Splines approx Spring Spindle spring Calipers pad bolts (inner / pad width outer) span 32" 32" 3" 3" single piston single piston 6 6 pinion centerline to knuckle centerline Chevy 79-87 88-91 K30 K30 crew cab kingpin kingpin pass.hubs wms) 69. spring pad span.5 V-30 1984-85 K-30 1984-88 CUCV 1982-87 K-30 1981 K-30 1979-80 K-30 1977 K-30 1977.com/tech/billavista/60_front/index.5" single piston single 6 http://www.Extreme Four Wheel Drive Page 4 of 23 603643 DODGE 603500 DODGE 610517 DODGE 610236 DODGE 610605 DODGE 610428 DODGE 610426 DODGE 610405 DODGE 610398 DODGE 610357 DODGE 610341 DODGE 610332 DODGE 610440 DODGE 610638 DODGE 610739 DODGE 610738 DODGE 610730 DODGE 610729 DODGE 610723 DODGE 610722 DODGE 610720 DODGE 610714 DODGE 610616 DODGE 610637 DODGE 610636 DODGE 610635 DODGE 610622 DODGE 610619 DODGE 610618 DODGE 610617 DODGE 610719 DODGE 610220 FORD 610023 FORD 610255 FORD 610305 FORD 610313 FORD 610371 FORD 610432 FORD 610460 FORD 610741 FORD 610610 FORD 610445 FORD 610295 GM 610202 GM 610201 GM 610159 GM 610132 GM 610057 GM 603728 GM 610033 GM 603624 IHC 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 60 FRONT 1976-80 D-600 1975 D-600 1995-96 W3500 1985-88 D-600 & D-700 1996 W3500 1994-94 1/2 W3500 1994-94 1/2 W2500 HD 1993 D-600 & D-700 1992 D-600 1991-91 1/2 D-600 1989-90 D-600 1989 D-600 & D-700 1994-94 1/2 W2500 HD 1997 W3500 1997 1/2 W2500 HD 1997 1/2 W200 HD 1997 1/2 W3500 1997 1/2 W3500 1998-98 1/2 W3500 1998-98 1/2 W3500 1998-98 1/2 W3500 1997 1/2 AIR FORCE TOW VEHICLE NON-ABS 1996 1/2 W2500 HD 1997 W3500 1997 W2500 HD 1997 W2500 HD 1996 1/2 AIR FORCE TOW VEHICLE NON-ABS 1996 1/2 W3500 1996 1/2 W3500 1996 1/2 W2500 HD 1998-98 1/2 W2500 HD 1985 F-350 1978-79 F-250 & F-350 (SNOW FIGHTER) 1986-88 F-350 MONOBEAM DRW 1988 F-350 MONOBEAM SRW 1988 1/2-91 1/2 F-350 MONOBEAM SRW 1992 F-350 (Balljoint) 1993-93 1/2 F-350 (Balljoint) 1995 F-350 (Balljoint) 1997 1/2-98 F-350 (Balljoint) 1996 1/2-97 F-350 (Balljoint) 1994 F-350 (Balljoint) 1988-91.Pirate4x4. OEM Years Application knuckle diff gears springs width (wms.Com . The lockout hub on a D60 is approx 4" in diameter.25" internal 35 / 30 36.html 8/22/2007 . regular regular leaf leaf 67.jpg (53796 bytes) The 10 bolt diff cover measuring 10.Pirate4x4.5" 2. pass.jpg (41207 bytes) This is what a kingpin knuckle looks like Dcp_4521 copy. Dcp_4515 copy.5" dual piston 5 Identification: The following pics are of a 1979 Ford F-250 Camper Special High Pinion Dana 60 Dcp_4512 copy.jpg (47866 bytes) The easiest way to tell a D60 from a D44 is the diameter of the hub.25" internal 35 / 30 31.Com .5" internal 35 / 30 external 35 / 30 32.5" 5 92-99 F350 balljoint drivers reverse leaf 69.5" more to drivers side than 78-79 85-91.notice how the pinion enters above the centerline of the axle tubes.Extreme Four Wheel Drive Page 5 of 23 92-93 85-88 700 kingpin pass.com/tech/billavista/60_front/index.5" 75.jpg (60524 bytes) The RCD60 has a high pinion diff .5 F350 kingpin drivers reverse leaf 69.25" internal 35 / 30 36. The following pics are of a 1980 Chevy K30 D60 Chevy D60 has passenger side diff and kingpin knuckles http://www.125" diameter axle tubes. 3. and kingpin knuckles identify this as a 79 Ford HPD60 Dcp_4510 copy.5".5" 32. On an RCD60 the centerline of the pinion is 1-1/8" above the centerline of the axle shafts.75" x 11.5" dual piston dual piston 5 about 3.pirate4x4.5" piston single piston 6 6 DRW D-600 & kingpin D-700 Ford 78-79 F250/F350 kingpin drivers reverse leaf 69.5" more to drivers side than 78-79 about 3.5" 2. Lug pattern alone is insufficient as there were 8 lug D44s. http://www.pirate4x4.jpg (36951 bytes) Dodge D60 with external mounted drive flange. In the reguar cut Dana 60s the pinion centerline is 1-1/8" below the centerline of the axle shafts. Note nonsymmetrical bolt circle. Dodge D60 with external mounted drive flange.jpg (114189 bytes) Notice the Chevy pinion is much lower than the RC version.Com . This picture applies to any kingpin Dana60 front axle Photo courtesy Steve Gerstner Miscellaneous Front D60 pics: Chevy 6 bolt knuckles.Pirate4x4.com/tech/billavista/60_front/index.jpg (68947 bytes) Chevy outer knuckles.jpg (92442 bytes) Dcp_5033 copy. and is different from Ford knuckles Chevy 6 bolt spindle. Ford 5 bolt spindle.html 8/22/2007 . Mounting holes are NON-symetrical and the spindle will only fit one-way Photo courtesy Shaker dodge 60 with external flange 2. Note blue arrow indicates clearance for large singlepiston Chevy brakes. Spindle will only fit on knuckle one way.jpg (50729 bytes) dodge 60 with external flange 1.Extreme Four Wheel Drive Page 6 of 23 Dcp_5037 copy. Dodge D60 with external mounted locking hub. center dust-cap removed. spool. regular cut: 4. So if you bought aftermarket 5. fully dressed single wheel front Ford RC 60 complete. so it could just go on the stock carrier.30T 1. limited slip) for your RC60 . You buy aftermarket gears first .html 8/22/2007 . and won't go on that carrier. Max load (SRW): 4500lbs.com/tech/billavista/60_front/index. The 2000+ RC60 Fords are offered with stock gears as low as 5. is this:. locking hub to hub 460-480lbs Max steer angle = 40 degrees Cover Bolts: 10 Diff cover 10-3/4 X 11-1/2" Side gear spline24/48 pitch.56 and up locker" but you get hooped because the gears are thick.56 and up carrier (called a 4-series carrier) you need to measure the distance from the face where the ring gear sits. Weight.labelled dimension "A". 3.I imagine.Extreme Four Wheel Drive Page 7 of 23 Photo courtesy DRM Dodge 60 with external hubs copy.10 and down carrier.10 down / 4.2760" 29 Involute Splines Carrier split.Pirate4x4.13 gears . Now . they would just go on the locker. fully dressed single wheel front Chevy 60 complete.that way .jpg (33582 bytes) Dodge DRW Front 60 external locking hub Photo courtesy Larryboy Specs: The following info is true of all front Dana 60s covered by this article. depending on where you buy it from.Com . . To distinguish a 4.D.56 up Carrier split. Continuous: 1500 Lbs.Ft.they are thin and go on the same GM/Dodge 4.4370" Ring Gear Diameter: 9 3/4" Ring Gear Bolts: (12) RH Thread 1/2" X 20 Pinion Shaft Diameter: 1. and is the same as the GM/Dodge 4.these figures unconfirmed Axle tube dia.jpg (27600 bytes) Ford 60 spindle. Then you buy a locker by ratio. rebuilt by Boyce Photo courtesy Boyce Equipment Boyce Chevy 60f.38 gears for RC60 .jpg (8527 bytes) Boyce chevy 60f 2. The problem you might run into.I must need the 4.250 P. Also note.namely part # 706040X. BUT .pirate4x4.10 and they're thick. locking hub to hub 518lbs Weight. not make and model. When aftermarket vendors started making gears lower than 4.56 up carrier.jpg (12734 bytes) Chevy D60.if you already had aftermarket lower gears. they ask "year/make/model" and based on that would likely sell you the 4. http://www. I don't know if Spicer is the only manufacturer offering thin RC60 gears .=9. to the end of the carrier.but the bottom line is .they would likely be thick.125".10 down carrier . locker.5" Weight center section = 120lbs.10 and down carrier (called a 3-series carrier) from a 4. Max torque short duration: 5550 Lbs.the Ford RC60 was never offered stock with a ratio lower than 4.but these are not thick to go on the same old 4.30 and down go on the 4.jpg (28418 bytes) Chevy D60.10 in those years.they made the ring gear thick.625" Pinion Splines: 1.750".10 down Detroit . rebuilt by Boyce Photo courtesy Boyce Equipment im000057.10 carrier . tooth width 1.when dealing with an RC60. wall thickness 0.10 for RC 60s . as shown in the following pic .e. The carrier break is 4.Ft.38 . reverse cut: All use same carrier ** ** Note: The carrier is the same for all Ford RC 60's UP TO 98.lower than 4. and naturally you'd think "I have 5. Ring Gear dia. you do have to match your carrier and gear set.if you buy an aftermarket carrier (i. pirate4x4. the diff cover gasket for a Chevy and Dodge Dana 60 is part number 34687.com/tech/billavista/60_front/index. Note.360" Carrier construction: malleable iron (fine grain cast iron) Ring and Pinion construction: 8620 heat treated Differential housing construction: Nodular iron Axle tubes construction: mild steel Inner knuckles (aka tube forks. For an exploded view of a Ford Dana60 click HERE: (note.Com . Ford.10 and down. Refer to the diagram below for picture / location of the part. you can use information in the chart to infer facts. http://www.2. but for a Ford it is listed as Ford 60F variable parts table when you look it up on Dana s web site.0. In the same vein. The same goes for parts like the diff cover fill plug and king pin cap grease fitting.56 and up Spicer part number 706041X) Dimension A is 2. However.. The Description column is the name of the part as it is commonly known. and Dodge front kingpin Dana 60s as indicated in the table below in the indicates Ford.forged. using the chart we can see that the diff cover gaskets and even the cover bolts interchange. For example. F is the description of the part according to Dana s web site. or the information is no longer available. and the column Dana s Description interchange between column. premium low-carbon mild steel Outer knuckle construction: malleable iron Axle tube to diff interference fit: . which I m pretty sure will all interchange but I can t swear to it. even though they are not presented as such. For an exploded view of the Chevy Dana60 click HERE. For example. where C indicates Chevy. Dana does not list the same part number for Chevy and Dodge diff covers.4 liters) 80w90 hypoid gear lube Wheel hub hole for 1/2" wheel studs(Ford '76-'79) .. end forgings.003" .006" .25" Differential fluid capacity . and D for Dodge.6 pints (3.1 5/16 Diameter of kingpin cap .0.600" Front Dana 60 parts interchange: The following parts interchange between Chevy. for these 2. so from that. the absence of a part on this list DOES NOT mean it is not the same / does not interchange it simply means that there was not a Dana part number listed for that part for all 3 manufacturers on Dana s web site. and knowing they are both standard cut low pinion Dana 60s.580" Wheel hub hole for 9/16" wheel studs (ford 85-97) . This info can be extremely useful when figuring out what parts can and cannot be used on an axle or custom project. This is usually because either a manufacturer uses their own part. or "Cs") .0" D60 pinion nut size .Extreme Four Wheel Drive Page 8 of 23 For a 3 series carrier (4. Note. own part number. Click for large view.html 8/22/2007 .005" Distance between axle tube centerline and bottom of diff: 6.Pirate4x4. Spicer part number 706040X) Dimension A is 2.010" Axle tube to inner yoke (C) interference fit . the pic is of a Dodge Dana 60. but I m fairly certain all 3 are the same. the diagram numbers in the pics do not correlate with the table below). Other sections of this article lists parts that are commonly know to interchange between axles.225" For a 4 series carrier (4. we can pretty safely infer that the covers do interchange. GREASE SEAL .KING PIN .pirate4x4.DIFFERENTIAL SHAFT DIFF SHAFT SEAL & GUIDE TUBE KIT .PINION BEARING INNER INNER PINION BEARING KIT KIT .Pirate4x4.DIFF BRG ADJ SHIM (INC 1 Carrier Cross pin Inner axle seal King pin rebuild kit Upper kingpin seal Lower kingpin seal Lower kingpin bearing oil seal http://www.PINION NUT NUT .DRIVE GEAR (QTY 12) PINION THRUST WASHER THRUST WASHER LOCK .Com .OIL BAFFLE PINION BEARING Dana s Description SLINGER .Extreme Four Wheel Drive Page 9 of 23 Dodge Dana 60 front exploded.DIFFERENTIAL BEARING CA DIFFERENTIAL BEARING KIT KIT .jpg (148352 bytes) Huge thanks so Steven J Meyer for providing much of the raw data on his website. Diagram # 003 004 005 006 Dana / Spicer part number 34643 70604x 706359x 708020 Description Front pinion oil slinger Front pinion bearing and race Pinion shims Interchange between CDF CDF CDF D only C & F # 706375X 30982 007 008 009 010 012 013 017 018 020 021 022 706045x 42737 42449 34592 30275 30271 34822 34687 48632-1 706047x 708012 Rear pinion bearing and race Pinion thrust washer Pinion seal Pinion Yoke slinger Pinion nut washer Pinion nut Diff cover bolt Diff cover gasket Diff main bearing cap bolt Carrier bearings Carrier shims C&F CDF CDF CD CD CDF CDF CDF CD CDF CDF D only C & F # 706378X 024 026 027 028 029 030 031 30266 34367 34729 34730 44810 30263 36487 706395x 032 033 034 620058 37305 41777 Ring gear bolt Spider gear Side gear thrust washer Spider gear thrust washer Roll pin cross pin CD CDF CDF CDF CDF CDF CD CD CD CDF CDF BOLT .BEARING SEAL .CARRIER COVER (QTY 10 GASKET .com/tech/billavista/60_front/index.PINION BOLT .PINION BRG ADJ SHIM KIT .END YOKE WASHER .CARRIER COVER BOLT .PINION SLINGER .DIFF & PINION ADJ SHIM OUTER PINION BEARING KIT THRUSTWASHER .html 8/22/2007 .KING PIN PARTS SEAL .UPPER RETAINER . 5 BS BS 3-4-5731-1X 34592 3-4-12211-1 3-4-5721-1 http://www.KING BOLT .5000 1.2760 1.pirate4x4. NOTE: D is the Ujoint cap diameter E is the outside dimension across the joint from cap to cap R is the diameter of the machined seal surface Q is the length though the hole.219 D 1.5000 1.8750 1.2760 1.188 3-70-28X 1.Extreme Four Wheel Drive Page 10 of 23 035 041 044 044 045 046 047 048 051 052 053 054 056 056 057 058 059 060 062 063 064 065 075 706150x 30875 37307 620132 37300 620180 41886 37302 37879 37299 500357-13 500412-13 37308 700014 620062 37312 37311 620063 36880 48816 706411x 706074x 707083X Lower kingpin bearing and race Upper kingpin cap bolt Upper kingpin cap gasket Upper kingpin cap Kingpin spring Kingpin spring retainer Upper kingpin bushing Kingpin Spindle stud Lower kingpin cap Lower kingpin cap lockwasher Lower kingpin cap bolt Stub shaft slinger Spindle bearing and seal kit Inner spindle seal Spindle thrust washer / spacer Outer spindle seal Spindle bearing Spindle nut Hub seal (inner wheel bearing seal) Inner wheel bearing and race Outer wheel bearing and race 30 spline drive flange kit CDF CDF CDF CDF CDF CDF CDF CDF CD CDF CDF CDF CD CD CD CD CD CDF CD CD CDF CDF CF KIT . Joint Ujoint width series E 1310 3.5000 1.0 UB UB BS 2-4-3671X 2-4-4291X 230421 34592 2-4-3661 2-4-4031 2-4-8421-1 1330-F 3.Pirate4x4.062 2-94-28X 2-70-18X 2-94-28X 2-70-18X 2-70-18X 1.5 20.2760 1.2760 1.8750 1. Note the differences in max allowable joint angles .2760 1.5000 1. and as such.BEARING .062 2-94-28X 2-94-28X 2-70-18X 1.KING PIN PIN .SPINDLE NUT .9380 2.625 1.8750 1.html 8/22/2007 .NEEDLE BEARING SPACER .LOW SLINGER KIT .SPINDLE SEAL . U-bolt kit Strap kit Diameter Cap Major Bearing Strap (BS) or U-bolt (UB) UB BS UB BS BS Ground Hub diameter (R) Length Centerline through to end (S) hole (Q) Joint Angle Yoke plus slinger part # Slinger part # Yoke Part # 2-4-3781X 2-4-3801-1X 2-4-3801X 2-4-6551-1X 2-4-8391-1X 30798 34592 34592 34592 34592 2-4-3771 2-4-3791-1 2-4-3791 2-4-6541-1 2-4-8331-1 1330 3.9964 18.2760 1.5000 2. according to Drive Train Specialists.125 2-94-58X 2-94-58X 1.LOW BOLT .9380 2. and while not absolutely critical should be close o as to allow proper pinion nut tightening S is the total "length" of the yoke.0000 22.9690 3.1880 20.8750 1.8750 1.GREASE INNER WHEEL BEARING INNER WHEEL BEARING KIT KIT DIFF PLATE AND DISC (T/L) Front Dana 60 Pinion Yoke options: Refer to following diagrams when reading chart.8750 1.UPPER (RH ONL SPRING .HEX CAP .2760 1. assuming Q is close.9380 2.BRAKE MOUNTING SEAL .2760 1.0 UB UB 2-4-8051X 2-4-5311X 41195 34592 2-4-8041 2-4-5301 1350 3.KING PIN .KING PIN .0000 3. will affect driveshaft length slightly Bold text in the table indicates factory application.9380 2.PRESSURE GEAR BUSHING .Com .9380 2.2760 1.0 18.KING PIN BEARING LOWER LOCKWASHER (KING PIN CAP .8750 1.8750 1.0 22.L NUT .2760 1.5000 1.7000 2.5000 1.KING PIN CAP CAP .may be important / helpful in some applications.HEX TAPERED GASKET .5000 1.HEX (KING PIN CAP .625 1.0 dia.OIL NEEDLE BEARING .0 18.2760 1.5 22.2760 1.com/tech/billavista/60_front/index.WHEEL BEARING SPINDLE SEAL .8750 1.8750 1.5000 2.8750 1.8750 1.5310 2.5000 3.5000 1.625 1.9380 18. 38 5.5000 3.0 BS 2-4-7681-1X 34592 2-4-7671-1 Pic shows 1310 v. http://www.88 5.pirate4x4.8750 1.then back off approx.1850 3.188 1.com/tech/billavista/60_front/index.10 carrier) reverse regular / reverse / reverse thick regular / reverse / reverse thick regular / reverse / reverse thick regular / reverse regular regular regular 41-7 37-6 43-6 41-9 39-8 41-8 Teeth (ring .0000 3.3590 30.5 BS 3-4-13391-1X 34592 3-4-9531-1 7290 1.Extreme Four Wheel Drive Page 11 of 23 1.2760 1. not being quiet.54 3. 1350 yoke Assembly Specifications: Item Pinion bearing preload (new) Pinion bearing preload (used) Pinion bearing HP60 used in rear Backlash front wheel bearing freeplay Ring gear bolt torque Bearing cap bolt torque Cover bolt torque Pinion nut torque Cover fill plug Yoke U-joint bolts wheel brg adjusting nut wheel brg locknut Kingpin Upper and lower kingpin cover bolts Spindle nuts (the ones that hold the spindle to the knuckle.0 BS BS UB 3-4-11891-1X 3-4-5711-1X 34592 34592 3-4-11851-1 3-4-5701-1 3-4-8731 1480 4.2760 1.125 1.2760 1.188 1.86 6.10 4.5000 3.1880 3.5 30.5 22.html 8/22/2007 .8750 1.pinion) 46-13 41-11 41-10 Anything over 5.2760 1.2760 1.5 22.5000 3.Pirate4x4.73 4.8740 1.5 BS BS 3-4-13031-1X 3-4-13031-2X 45799 45799 3-4-12771-1 3-4-12771-2 1410 4.5000 22.2760 1.8750 1.188 3-70-28X 3-70-28X 3-94-18X.30 4.) Spec 20-30 8-10 12-20 6-10 1-10 110 80 30-40 240-300 40 8-15 50 50-70 500-600 70-90 65 Unit inch pounds inch pounds inch pounds thousandths of an inch thousandths of an inch foot lbs foot lbs foot lbs foot lbs foot lbs foot lbs foot lbs .13 5.5000 1.17 Cut regular / reverse regular regular / reverse regular (uses 4.8750 1.8750 1.0000 22. 1.30 4.2760 1.1880 22.Com .s.375 3-70-38X 1. 90* foot lbs foot lbs foot lbs foot lbs Dana 60 Gear ratio availability: Ratio 3.56 4.38 Dana says are for industrial applications only.17 7.5000 3.5000 1.4200 1.8750 1. meaning they are cut for strength. one need only order the standard stock part number or application. a Dana 60 30 spline stub shaft (top) Photo courtesy D60 image005. http://www. Photo courtesy Wolf359 1978 and later Stock Dana 60 outer 30 spline stub shafts (pn 40955) are 1.Pirate4x4.pirate4x4. nobody makes thick gears for the standard cut D60 front. For comparison.more on this later The 3-82-871 stub axle is used in Dana 70BF front axles assemblies. To use them in a Dodge D60 with external hubs. but around '80.625 '91).Com . A Dana 44 19 spline stub measure 1. In order to run the 35 spline stub shafts in an axle that has Chevy/Dodge knuckles-out with "internal" style hubs. Dana 60 limited-slip availability: Dana Trac-lok 4.10 & down pn 707090-4X / 4. pavers. you should get the larger shafts.56 & up pn 225SL29A Powertrax Lockright pn 2620 Powertrax No-Slip pn 92-0460-3500 (for open carrier) pn 92-0460-3520 (for Trac-lok carrier) Full Spool (35 spline only) Front D60 Stock Spicer Axleshafts: Older stock Dana 60 35 spline inner axles (particularly pre-1980) neck down from 1. image003. assuming your supplier doesn't have any really old stock.250" at the shank.500 at the splines..56 & up pn RD35 Detroit Locker 4. The Dana 70 BF front axle is an "off-highway equipment" axle also used in forklifts. and taper up to 1.10 & down pn 225SL29B / 4. These axles are the open knuckle style Dana 70 front.. etc.375" at the shank.562" at the seal surface. This picture illustrates the older neck-down shaft on top. The part numbers are the same for the whole run ('77- Later Spicer inner axles (1980+) are 1. Only the old style closed knuckle 70's had lockouts and they used an external style hub. 1.jpg (12139 bytes) Dana 60 30 spline stub (right) vs.Chevy.060" at the shank Spicer 35 Spline stub shafts pn 3-82-871 (originally for D70.5 at the splines to 1. but work in GM/Dodge D60 without modification) are 1. and the later big axle below. and. all you have to do is swap in the stub shafts and a 35 spline lockout or drive flange (sources for these listed later in article). tow motors. These particular shafts are Dodge Dana 60 shafts. (They were gradually phased in over a few years) In order to upgrade an older "neck down" shaft to the larger models.3" in the middle of the shaft. Dodge.56 & up pn 707097-4X Dana Power-lok Dana 60 locker availability: ARB 4.10 & down pn RD36 / 4.155" at the splines and 1. they changed to the bigger shafts. The axles are used in very heavy duty light trucks (under 2 1/2ton) such as Ford f550 forestry trucks or rescue and firetrucks. and Ford.com/tech/billavista/60_front/index.jpg (28870 bytes) This pic illustrates a Dana 44 19 spline stub shaft (bottom) vs.5 at the splines and 1. the only trick is sourcing or fabbing a 35 spline external lockout or drive flange (more on these later too). According to the Spicer catalog/index it was never produced with lockouts. the Dana 60 35 spline stub (left).Extreme Four Wheel Drive Page 12 of 23 As far as I know. Warn makes 35 spline lockouts for the internal style hub.and the external style 35 spline lockout has long been discontinued.3125" at the splines (major diameter) and approximately 1. at the largest diameter. They can work in a Ford d60 too .html 8/22/2007 . This is true for all 3 . 5 1.Com .3 1.5 1.98" 12.Extreme Four Wheel Drive Page 13 of 23 image007.5" 1. Spicer 35 Spline stub shafts pn 3-82-871 Stock 30 spline stub shaft in D60 hub 30sp stub in hub.68 36.5 1.jpg (26351 bytes) 35 spline stub shaft in D60 spindle 35spline stub in spindle.com/tech/billavista/60_front/index.97" 16.jpg (26055 bytes) Dana 60 30 spline stub (left) vs.5 2000+ Superduty http://www.4" 35 35 1.00 35.com Photo courtesy Shawn Spickler. Photo courtesy Wolf359 image009.07 17.5" 1.5" 1.3" 1. Off-road.97 11.68 15.17" 11.html 8/22/2007 .5 1. the Dana 60 35 spline stub (right).com Photo courtesy Wolf359 Photo courtesy Wolf359 Stock Dana Spicer Axleshaft specs: Manufacturer (oem) Chevy Application long side inner short side inner stub (outer) Spicer part # 660182-6 660182-5 40955 660182-6 660182-5 40955 660182-2 660182-1 40955 660182-10 660182-11 660182-36 660182-1 620085 76110-1x 76110-2x Length (inches) 35.jpg (26077 bytes) Photo courtesy Shawn Spickler.3" 1. the Dana 60 35 spline stub (right).62" 35 1.00 35.56 18.Pirate4x4.5 1.13" 15. preballjoint) long side inner short side inner stub (outer) (will work in Chevy) (won't work in Chevy) Ford long side inner short side inner long side inner short side inner stub (outer) long side inner short side inner stub (outer) long side inner short side inner stub (outer) long side inner 78-79 F250 and F350 78-79 F250 and F350 2000+ Superduty 2000+ Superduty 2000+ Superduty 76660-2x 76660-1x 36.jpg (108936 bytes) 35 spline stub shaft in D60 hub 35sp stub in hub.5" 1.5 Notes Dodge (external hubs) long side inner short side inner stub (outer) Dodge (internal hubs.39" Spline 35 35 30 35 35 30 35 35 30 35 35 35 35 30 35 35 Diameter 1.5 2000+ Superduty 2000+ Superduty 2000+ Superduty 76150-1x 37. Off-road.40 37.pirate4x4.5" 1.67 12.3" 1.00 34.5 1.07 17.67 12.jpg (101817 bytes) Stock 30 spline stub shaft in D60 spindle 30sp stub in spindle.5" 1.jpg (28018 bytes) Dana 60 30 spline stub (left) vs.20" 15.90" 9. up to 32" long (5-332x.97" 24. and heat treat is: 30 spline 35 spline: ~40% Front Dana 60 axle U-joints: Dana 60 Ujoints are 1480 series . while the outer shafts are available in both 30 and 35 spline.9.94 22.721 ft/lbs The Formula is: Yield Torque (in/lb)= Tensile Strength ( psi) x polar moment of inertia/ radius of material The theoretical axle size by spline to percent strength increase.188" across the joint Original hot forged joint: Spicer 5-332X .html 8/22/2007 .1 3/8" U-Joint cap diameter. induction hardened) 30 Spline .00" 35 uses 5-88x ujoint uses 5-332x ujoint uses 5-88x ujoint Who makes aftermarket alloy axles for a front Dana 60? Moser Engineering make an alloy 35 spline D60 front axle inner or outer.50 35 12.50" 8.600 ft/lbs.72 17.solid cross. $395 per pair " Dutchman also sell Spicer Front Axle Shafts: These are not aftermarket alloy or chrome-moly axles. but it is not yet available.pirate4x4. thru hardened 30sp 1.50 39.40" 35 1.966.53 16. It's made out of the same material as their race axles (1541M. The newest Moser Engineering indestructible axles ship in just two-days from the order date.31" 6.044. non-greasable New Cold Forged joint (Spicer calls these the Greasable: Spicer SPL55-4x also called 5-733x Permanently Sealed: SPL55-3x. Designed for use with Spicer #5-332X u-joints. They come with no warranty.Extreme Four Wheel Drive Page 14 of 23 short side inner stub (outer) Miscellaneous inner inner inner inner inner inner inner inner inner short side inner long side Dana 70 inner inner inner inner stub (outer) stub (outer) 76150-2x 15. They want $395 for the outers a pair and the same for the inners a pair. They are $395 a pair for the inners and the same $395 for a pair of outers.923.16 44. They are making them with the option of 30 or 35 spline outers.5 ft/lbs 35 sp 1.5 2000+ Superduty 2000+ Superduty 660182-3 660182-4 660182-34 660182-12 660182-26 660182-30 660182-21 660182-22 76660-1X 76660-2X 660180-1 660180-2 660180-5 660180-6 3-85-591 3-82-871 21.5" 14. in the Ford or Chevy configuration.25 35.200 ft/ lbs.39" 9.6.50 16. 1 3/8" U-Joint cap diameter only) New Spicer Outer shafts: Dana 60 (Chevy & Ford 30 & 35 spline) $160 $76 Pair $295 $140 How strong are the different axle shafts? (note these figures are subject to much debate) Standard Dana axles (1040 steel.19 39. but stock Spicer alloy.1 ft/lbs 35 sp 1. From their web site: Single New Spicer inner shafts: Dana 60.06 24. 4.2 ft/lbs.31" 9. Aftermarket 4340 steel. induction hardened) and does not have any taper the full length.com/tech/billavista/60_front/index. the Moser 60 Front Axles are available in both inner and outer shafts. Moser Engineering (1541m. assuming same material. induction hardened) 30 sp 1. also called 5-806-x Spicer Life Series ) http://www.Pirate4x4. diameter. Inner shafts are available in 35 spline. Here's what Moser says about their new axles: "These virtually indestructible front axles are much stronger than stock. They are supposed to be developing an aftermarket alloy shaft.Com .44 32.17" 36. due in part by the induction hardened alloy steel and also the fact the axles are beefed-up considerably around the ujoint.94 14. 35 spline . dana. spacer.. all will interchange between Ford. or spring ## 4340 induction hardened and the caps will be anodized black with a little logo on them. or seen any published numbers in any literature from Dana Spicer. or the use of custom D60 front shafts designed for full circle snap rings. it does so at the base of the trunion where the hole bottom is located.Pirate4x4.They will go for about 175 bucks for the pair. if we examine a pic comparing the old and the new.Com .. superceded by SPL55-4x 5-806-x is active superceded by SPL55-3x Are the "new" cold-forged Spicer joints stronger than the old 5-332X? There have been many widely varied reports on the internet about this. Oftem when a front Dana 60 ujoint breaks. not the dust cover.Extreme Four Wheel Drive Page 15 of 23 5-88x u-joint is that listed for some stock Dana70 applications. It's quite likely that the smaller hole and supposedly stronger manufacturing process will net some increase in strength in the shaft of the trunion. Chevy. Be aware that these u-joints are designed to use "full-circle" snap rings and so will require a little machining of the ears of the yokes of stock shafts to allow the snap-rings to fit. The other option. and likely last word in ultimate D60 ujoint strength are the new 4130 forged ujoints from CTM racing. It is the same size as a 1480 series (5-332x). These ujoints are also much stronger than stock Spicer shaft yokes Front Dana 60 locking hub and drive flanges: Assuming correct match with splines on stub shaft.html 8/22/2007 . Note. according to the Dana/Spicer website (http://www2.com/tech/billavista/60_front/index. Part number is the CTM ujoint for a front Dana 60 axle. made for front axle The Warn hubs are actually made for the 9" or D60 full float rear kit.com/expert/ ) 5-332x is obsolete 5-88x is active SPL55-4x is active SPL55-3x is active 5-733x is obsolete. if only due to the cold forging process and smaller grease hole diameter. I have been unable to get any confirmation of this. However. with a lot of figures around 20% being published. but uses external snap-rings for retention (like a driveshaft ujoint). snap ring.pirate4x4. Type Drive Flange Inner Splines 35 35 Style Internal Internal Manufacturer Warn Spicer Part number 39346 620861 Picture 1 Notes full float drive flange kit (pair) single drive slug. and Dodge Internal style hubs. Unfortunately Long discontinued ^^ 35 35 30 30 30 Locking Hub 35 35 35 Internal External Internal Internal External Internal Internal Internal Poly Performance Picture 2 Spicer Warn Spicer Spicer Warn Warn 38787 Spicer 38786 Single hub 62672 Single hub Pair of hubs 26049x 39340 37994 New.. warn calls them "Heavy Duty Rear Full Floater Hublock" ** Standard 30 Internal Warn 11690 Premium 38826 http://www. However. it seems reasonable to assume at least some marginal increase in strength. Teralow D60 locking hubs are made by Milemarker. from a 30 spline drive flange with the 35 spline drive flange.com Warn Heavy Duty Rear Full Floater Hublock PN 38787. we removed the blocker ring so the hubs work just like normal hubs. Off-road. there's nothing.Ford oem 30 spline locking hubs are 5 pieces vs.) . On a front end. any misalignment is taken up by the spindle bearing fit and the locking hub clearances.Warn 35 spline Premium locking hubs have been bench-tested to failure at 967 ft/lbs 35sp drive flange. The set screw is in there for the same reason. etc. ## Related Spicer part numbers: 37996 dust cover for drive flange (discontinued) 37997 spacer for drive flange ^^ Sources for external style 35 spline drive flanges include Dynatrac. 81 was the last year for them oem Single hub Single hub Unconfirmed. or custom made (often from some 35 spline side gears that are annealed and then welded to a drive plate that has the 8 bolt external bolt pattern drilled in it) Notes: . The blocker ring makes it difficult to lock the hubs because you have to rock or move the vehicle so the splines line up.jpg (80457 bytes) http://www. The blocker ring makes a solid stop for the rear hub gear to hit against and keep it from coming unlocked. Warn's two pieces (not including snap rings. You'll have to trim the spring short enough that it allows the BB to slide out of the detent within the hub.com warn blocker ring.com/tech/billavista/60_front/index. . . The blocker ring and set screw are mods specifically for the intended rear axle application. You can modify the set-screw as follows: Buy the following from a hardware store: 1 short set-screw (about 3/16 inch) 1 spring (smaller in diameter than the set-screw) 1 BB (or small ball bearing) Replace the Warn set screw with the BB/spring/set-screw combination. the blocker ring is not necessary.jpg (77441 bytes) Warn Heavy Duty Rear Full Floater Hublock PN 38787 Photo courtesy Shawn Spickler. Since this is such a pain. . plus its got a ujoint between the tube and spindle so the spring pressure on the gear is enough to keep it engaged.pirate4x4.You can use the dust cover (cap).jpg (29347 bytes) Warn 35 spline locking hubs specifically for 35 spline D60 front axles.Pirate4x4. listed as "Flange Mount Hublock 30 spline" Unconfirmed. Off-road. Most rear axles are bent and this creates a circular motion on the end of the shaft as the axle spins and this circular motion tends to unlock locking hubs by pushing the gear out against the spring pressure. Photo courtesy Shawn Spickler. listed as D70 lockout ** These do have lock screw on the dial and a positive blocker ring. WMS. snap ring. spacer. a fellow on the POR BB by the name of Donovan.Many folks have reported good success having 30 spline hubs and drive flanges broached for 35 splines.Extreme Four Wheel Drive Page 16 of 23 30 30 30 30 30 30 Internal Internal Internal External External External Spicer Superwinch Milemarker Warn 38428 Superwinch Milemarker Selectro 38370 Single hub 400541 Single hub 11034-01 400439 449 SS Single hub Pair of hubs discontinued.jpg (35561 bytes) 35 spline internal style drive flange Photo courtesy Wolf359 warn 35 spline hubs. The set screw is also a pain but some guys like the screw since it makes it harder for someone to mess with the hubs.html 8/22/2007 . showing "blocker ring" mentioned above. spring. PN 62672 Photo courtesy Shaker warn 35sp lockouts. Instead of having a "click" when you turn them to lock or free. and neither is the set screw. For a front axle. just to keep the dial from rotating and unlocking.Com . The allen wrench and set screw is used to keep the hubs in the selected position. measures 5/8" x 8 1/4" x 3 1/8" fit perfectly a leaf spring pack that measures 2 1/2" and there is another 1/2" left on the bolts. 90042 323-255-3639 Before After Front D60 part numbers: Miscellaneous D60 part numbers. and the work was done by: Knoll Racing 1811 North Ave.polyperformance. C.com/tech/billavista/60_front/index.Com .gmpartsdirect. Replaces existing 35 spline locking hub or drive gear assembly Here are some nice pics coutesy of 3/4tonYJ of some stock 30 spline Dodge externa. 51 Los Angeles.C. Chevy D60 SRW wheel hub 15635530 .Pirate4x4. He paid $85 for the pair. Black oxide with wax coating finish for corrosion resistance.$297 from http://www. Dana 60 Front Spindle Nut Socket Napa #775-9025 (I don't know if this is 4 or 6 prong) GM D60 spring plates Part numbers 370055 and 370056 Pep Boys Motormite U-bolt part # 35661 .com http://www. machined using the latest HAAS equipment. CA.N.$184 from http://www.com Chevy/Dodge D60 SRW wheel hub SS7009 . drive flanges he had broached to 35 spline and polished.Extreme Four Wheel Drive Page 17 of 23 New 35 Spline drive gears available from www.html 8/22/2007 .com Drive gears are made from 4140 and then heat treated.sixstates.pirate4x4. 95 Kit (2 nuts.com/tech/billavista/60_front/index. 34. & 35 032 033 Dana Spicer part number 706395x Description King pin rebuild kit Interchanges between CD 620058 ** 37305 Upper kingpin seal Lower kingpin seal CD CDF http://www.00 Parts Mike Washer (Pin style lock) #PM 33733 $1. one has the holes that index onto a pin on the lock nut (4 slot nut style . Not also the different lock-washer methods. The other has the "bend over" tabs . # 32. These are Dana patr numbers. 1 flat washer 1 lock washer) #PM 33732K $13.Extreme Four Wheel Drive Page 18 of 23 * Note: Apparently Six States bought the hub molds from GM & are reproducing them at a local foundry. Snap Rings for use with 35 spline stub shafts: Industry #143 or a Dynaline #22950. Spindle-nut part numbers and sources: Reider racing For one complete front axle you need four 33732(lock-nut). outer snaps.html 8/22/2007 .pirate4x4.although they both appear to share the same Dana part number. Diag. exploded diagram. 33. and pics.and they appear to use the same part numbers.438" diamater. Front D60 Kingpin rebuild: Commonly required kingpin rebuild part numbers.Com .Pirate4x4. two 33734 (flat washer). two 33733 (lock washer).lower pic). 1.95 Washer (flat) #PM 33734 $1.95 Dorman spindle lock nut kit #05303 for an 85 K30 are about $23 each Note: There are 4 and 6 slot locking nuts available . All 8 pieces for about $22. pirate4x4. 34.Extreme Four Wheel Drive Page 19 of 23 034 035 41777 706150x Lower kingpin bearing oil seal Lower kingpin bearing and race CDF CDF 041 043 30875 GM part no.com/tech/billavista/60_front/index. & 35 .Com .King pin rebuild kit pn 706395x Photo courtesy Shaker Kingpin rebuild kit from Parts Mike Photo courtesy PartsMike http://www.html 8/22/2007 .Kingpin pn 37302 Photo courtesy Shaker 045 .Kingpin spring pn 37300 046 . 0047-1750 37307 Upper kingpin cap bolt CDF Upper kingpin cover C 044 Upper kingpin cap gasket Upper kingpin cap Kingpin spring CDF 044 045 046 047 048 051 052 053 620132 37300 620180 41886 37302 37879 37299 500357-13 CDF CDF Kingpin spring retainer CDF Upper kingpin bushing CDF Kingpin Spindle stud Lower kingpin cap Lower kingpin cap lockwasher CDF CD CDF CDF 054 500412-13 Lower kingpin cap bolt CDF ** only sold in quantity 10 047 .Pirate4x4.Kingpin spring retainer pn 620180 Photo courtesy Shaker 32.Upper kingpin bushing pn 41886 048 . 33. Extreme Four Wheel Drive Page 20 of 23 Front D60 bearings and seals: Referring to the following diagram.pirate4x4.Pirate4x4. D60 front axle spindle / wheel bearings and seals are: Diagram # 57 59 60 57.com/tech/billavista/60_front/index.left 65 Description Inner Spindle seal Outer spindle seal Spindle needle bearing Spindle seal and bearing kit Wheel Bearing hub seal Inner wheel bearing cone (bearing) Inner wheel bearing cup (race) Outer wheel bearing cone (bearing) Outer wheel bearing cup (race) Outer wheel bearing cup and cone set (bearing and race) outer spindle collar (outer spindle locknut) inner spindle collar (inner spindle locknut) spindle nut Dana Spicer # 620062 37311 620063 700014 48816 565906 550583 565918 565905 Timken # 710044 710045 B2414 SBK3 240435 387-AS 382-A LM104911 LM104949 SET38 National # GM # 14012967 462811 1400967 14009626 Ford # D8TZ1175C D8TZ1175A D8TZ3123A Chrysler # 3894121 4089296 4086641 340435 387AS 382A 4TLM104911A 4TLM104949 BWLM104949LM1 2090539 9436882 142223 7451813 2852729 7451812 C5NNA767A C5NNA768A C7TA1239A C7TA1240A E5TW1239AA 568500 2953549 2825729 67 621027 68 660568 http://www. 59.html 8/22/2007 . 58.Com .right 65 .right 65 . and 60 63 64 .left 64 . so it should not cause a problem.Extreme Four Wheel Drive Page 21 of 23 69 not shown lockwasher inner axle seal 621028 62510 475960 15527650 D8TZ1175B T2560 ** For a larger interchange chart. If you do.note rotor/hub pinned together by wheel studs. the DRW hub 'bulges' . some don't.only to handle the rotational force on the brake rotor. Chicago Rawhide. just duplicate the ring from the original DRW hub outer wheel mounting surface. Also. Alternatively you can convert your front DRW hubs to SRW hubs as follows: Machine off the outer wheel mounting flange Machine the hub down enough for the wheel center to fit over if required (depends on wheels used). Some guys do this. is that the small inner tabs on the DRW rotor were never designed to carry the entire weight of the vehicle . bearings. DRW hub mounted. and there is plenty of meat there. Federal Mogul. so the holes are generally drilled out for press in studs. since GM was the only source for SRW hubs. Alternatively. at a cost of something like $1100US A pair. The SRW and DRW front axles are identical EXCEPT for the wheel hub and rotor . you could also weld on a custom spacer / wheel mounting surface to the rotor mounting tabs of the DRW hub. SKF. Not much needs to be removed.pirate4x4. (Assuming Chevy) It is impossible to re-tap the internal threads in the DRW hub to fine thread. and many more numbers click HERE: ** The following pics show some of the parts in greater detail. The later version has a nipple on the inner spindle nut that fits into a lockring and another spindle nut to secure it (pictured). Re-drill the holes where the rotor bolted to the bearing hub to fit the lug studs. allowing the use of the same brakes on either (as opposed to the SRW hub which uses the wheel studs to pin the rotor and hub together). The DRW wheel hub has a wheel mounting flange mounted on it about 4-5" from where the SRW wheel would mount. The problem with the "homebrew" machined version illustrated below. Because of this.com/tech/billavista/60_front/index.html 8/22/2007 . dually hub 2.note the distance between the rotor and wms. For that price. the holes in the DRW rotor are smaller than in the SRW rotor. as opposed to the SRW rotor holes which are larger to fit the knurled shoulder of the SRW wheel studs . and to allow the DRW trucks to carry a single spare tire mounted on the largely dished "budd" style DRW wheel. It became a popular procedure in the past. and the DRW rotor bolts are 9/16 coarse thread. since the DRW rotor holes need only to clear the 9/16 bolts. Pics courtesy of Shaker. Aftermarket wheels may not be an issue if they have larger center holes. The last difference is that between the DRW mounting surface and where the SRW mounting surface would be. the rotor is bolted to the DRW hub with 8 9/16-NC bolts inboard of the wheel mounting flange.jpg (32326 bytes) DRW hub removed. Sealed Power. To convert from DRW to SRW you can either swap on a complete SRW front hub/rotor assembly. This makes the DRW axle 4-5" wider on each side. that is certainly the best way to convert DRW to SRW axle.jpg (37895 bytes) DRW hub installed . now new hubs are available through SixStates for only about $165US each.Com . Machine the wheel mounting surface of the DRw hub rotor mounting tabs. and the rotor/hub bolted together. This was done to more closely match the width of the DRW rear axle.enough so that it will not fit through the center hole in the stock SRW wheel. SRW hub installed . Note the 9/16-NC bolts for bolting on the DRW rotor. showing (where applicable) Victor. You need to have this surface machined flat because it is flame cut and likely not flat.same spindle.jpg (39999 bytes) SRW hub mounted. However. with the numbers from the exploded diagram in blue. it is a direct swap or swap on a SRW hub and drill out the holes in the DRW rotor so it can be re-used. I would certainly not recommend this procedure for use on a vehicle that will ever see street duty.Pirate4x4. the rotors are identical and DRW rotors can be used with SRW hubs if the 8 holes are drilled larger. http://www. and lockout. Also. D60 spindle locknuts and washer D60 inner axle seal Earlier version uses a lockring with tabs that bend over the spindle nuts. Spindle bearing and seal kit. The SRW lug studs are 9/16 fine thread.other than that. Converting DRW hubs to SRW hubs: NOTE: This section is included because so many people ask about it. you may want to the wheel centering ring cut into this surface. in the same position as the SRW hub. so this is the stud I ended up using.since the mounted wheel clamps to this custom spacer.if you are going to buy new ones.Com . 3 inches long.303 . how once the wheel is bolted on .283 is the part number for the STANDARD 1 ton Chevy. Pic courtesy ColoradoK5's Beater74 DRW hubs machined side.562).pirate4x4.678 shoulder. which is the exact size of the hole I used. Bicknell Racing Products sells a wheel stud. 15/16 shoulder length. Standard class V interference fit (tight . It is identical in most measurements (including thread) to the 610-283. The shorter stud worked fine in my application.672. . DRW hub before. A 21/32 drill bit is . 9/16-18 thread. measure the knurl diameter carefully (mic it) and then have the holes drilled slightly undersize for a proper tight interference fit. 9/16-18 thread. Extreme CAUTION is required.jpg (59603 bytes) Finished DRW hub converted to SRW showing machining Photo courtesy Patooyee You can see in this pic.jpg (47531 bytes) Same hub as above .jpg (58923 bytes) Pic courtesy ColoradoK5's Beater74 DRW hub machined.the DRW ones are made for 9/16 bolts (. it fits 77-91 Chevy trucks.: 9/16-18 or whatever). Dorman part # 610 . I would drill them out . the entire weight and rotational force of the front end is supported by those welds. Dorman part # 610 . . and diameter of the 'knurl'. The studs go through the rotor and spline into the hub. I would just buy the SRW rotors Drill the hub holes out to accept the studs. and rotational torque/ braking force of the entire front end of the vehicle. and the fact that the measurement of the knurl will be the major diameter of the splines. but MEASURE TWICE.e.jpg (53133 bytes) A DRW converted to SRW. BRP2075. This stud was meant to be used in a hole drilled out to 43/64. I would shoot for a 15 thou undersize hole. 2. Pic courtesy ColoradoK5's Beater74 A note on studs: Basically when they list studs. In actuality.672. the SRW ones are made for wheel studs(~. Prob. BRP2051 is the lug nut that matches. which is 5/8 Course thread. If you have a set of good DRW rotors. Not recommended for street vehicle. the ones I measured never mic'd to more than .fits 77-91 Chevy trucks. They also sell another wheel stud.side view.656250.but not recommended for a street driven vehicle.Extreme Four Wheel Drive Page 22 of 23 Either Drill your DRW rotors out to accept wheel studs. DRW rotors are much harder to get and way more expensive than SRW rotors. DRW hubs machined backside. using a weld-on custom wheel spacer / wms Again . My friend Chad who did a DRW-SRW conversion reports: "If you find that even Dorman 303 is too small. Given the measured knurl size of .75 inches long. part number BRP2059. this would mean a hole diameter of . yielding an interference fit of 15. and often the length of the knurl (called the shoulder length). .7 thou. assembly) the interference (shaft bigger than hole) should be between 3 and 18 thou.640).semi-perm. 15/16 shoulder length. once assembled.657. and I can report that it fits quite nicely into a 43/64 hole. OR buy new SRW rotors. which is exactly the same. It is very important that the hole be drilled to the right size for the stud.those little tabs are supporting the entire weight. they list the thread and pitch of the studs (i. drill once! ** CLICK HERE TO GO TO PAGE 2 OF THE 60 AXLE TECH ARTICLE** [Page 1] [Page2] Get a GoStats hit counter http://www.800 shoulder length." The important thing here is to select the studs you need to use FIRST.678. OK in a light weight trail-only rig .75 inches long. which is the splined part of the stud.Pirate4x4. but I think any 5/8 course lug nut would work fine. but some people may want more stud sticking out. 2 17/32 long. The ONLY difference between the two rotors is the size of the holes .650 shoulder. except that it is somewhat longer and has a knurl of .com/tech/billavista/60_front/index.html 8/22/2007 . Given this. That should be just about perfect.685 shoulder with a . the length of the stud (which is the length of the part the lug nuts thread on to). but 3. Pirate4x4.pirate4x4.Com .html 8/22/2007 .com/tech/billavista/60_front/index.Extreme Four Wheel Drive Page 23 of 23 http://www. 88 I had to go with series 3 carrier. The Dana 61 also uses 3. series 2 being 4. at some point Dodge and / or Ford decided they wanted to be able to offer gears higher than the current highest ratio of 3.html 8/22/2007 .56 and up. forums. you can use a combination of ring gear spacer and thick gear set to allow the use of differentials and gear sets intended for the Dana 60. it is very similar to the Dana 60.reiderracing. That's the problem.5" axle tubes. The Dana 61 was common in Dodge front ends and Ford van rears. The difficulty with the Dana 61 is very limited gear and locker choices. but it could be doable with a thick ring gearset AND a spacer. the birth of the Dana 61.htm Are all End-forgings (inner knuckles or "Cs") the same? No. A new line or paragraph after a blank line indicates the opinion/info of a different person. and other sources make ring gear spacers for the Dana 61 . because of the design of the D60 the pinion head could not be made big enough to achieve a higher ratio.54 available in the D60. Changes since last update indicated in yellow text. which has a different casting that moves the pinion over 0. Reider racing< Randy's R&P.10 and down. bulletin boards.com/tech/billavista/60_front/index2. 2003 02:06 AM . Slagburn reports: to run a 4. April 21. (photos courtesy of RealJeep Man) Small "regular" or common version Large version http://www.25"-0. PLUS a . illustrated below. series 1 being 4. However.07 axle ratio. OEM (Dana / Spicer) there are at least 2 different versions.com/ringspacer.pirate4x4. Hence. [Page 1] [Page2] Front Dana 60 FAQ: Information gathered over several years from various websites.160" spacer.Com . What's the deal with the Dana 61? With mileage and emissions concerns rising. and e-mail lists. http://www.Pirate4x4. However.this allowed for a 3. nobody makes a full case locker for a 61. Other than that.Com Bulletin Board.Extreme Four Wheel Drive Page 1 of 16 Front Dana 60 Axle Tech PAGE 2 (Click on most pics for a larger version) Last updated: Monday.437" (conflicting reports) . The vast majority comes from the most excellent Pirate4x4. then the series 3. here's a pic of the end forging that Steve Gerstner is using in a front Dana 80 project ..Com .125 tube.but the sharp-eyed reader will notice that.. The dana 70 open knuckle front used this same forging but was bored for the 3.56" tube.html 8/22/2007 .com/tech/billavista/60_front/index2. it was used on the ford bottom load dana 60 front in '76 and '77.Extreme Four Wheel Drive Page 2 of 16 The heavy tube fork was used on the snow plow dodge dana 60 front for several years. and they have been known to crack and break in that area. this pic is of a Chevy knuckle .made from 6" plate!! Which outer-knuckle is strongest? 4x4 lore has it that the Chevy/Dodge knuckles are the strongest. ironically. Just for fun . the 60 is 3.pirate4x4. steve differential eng.Pirate4x4.so they're obviously not bulletproof either! http://www. This pic illustrates where.. inc. and it is reported that the Ford outer knuckle is thinner around the king pin... http://www.com/tech/billavista/60_front/index2.pirate4x4. . Can I machine a Chevy/Dodge spindle and turn it into a Ford spindle? I took the Dodge spindles to the lathe and turned them into Ford spindles.Com . . and come with high steer arms with bigger bolts and cone washers for $750 each.The external hub sticks out of the wheel hub more. The difference is where the outer wheel bearing resides.htm Photos courtesy WMS The other is a fellow on the Pirate4x4.Finally. the Dodge/Chevy. The Ford stuff is right at 5/8" shorter. but shouldn't be too much of an issue if they are kept religiously tight . Photos courtesy Camo Why do so many prefer internal to external lockout hubs? Many folks believe the external style lockout hubs that are mounted to the wheel hub with 8 9/16" bolts are weaker than the internal lockouts that are splined to the wheel hub. .wagonermachine. as there are no 35 spline external lockout hubs.both of whom are known for quality but also high prices.The only 30 spline external drive flanges available are the OEM / Spicer units which would have to be sourced used or NOS. The Dodge calipers stands and calipers (same as Chevy) line up fine on the Ford rotors.both the number of options availability. or custom made units. then cut off the same amount off the end of the spindle.The only confirmed "new" external 30 spline lockouts I could find were the Milemarker "Selectro" brand which many have reported are fairly weak . Take the Chevy spindles and use the Ford spindles as your pattern for your lathe work. generally external style hubs are less desirable. The Ford is 5/8" closer to the inner bearing vs. Inner bearing and wheel seal surface is/are all the same.Converting to 35 spline stub shafts with external lockouts is more of a challenge. because of the issues listed above. Basically. This is likely true if the bolts are allowed to loosen. His contact # is (916)852-7109 These are 100% fabricated. and is therefore more prone to catching on rocks and getting damaged.Pirate4x4.Extreme Four Wheel Drive Page 3 of 16 Photo courtesy Camo Are there any aftermarket outer knuckle options to address these weaknesses? There are only 2 sources I am aware of for aftermarket outer-knuckles. http://www.html 8/22/2007 .which in itself can be a PITA and therefore a drawback. Other drawbacks to the external style lockouts are: . Base all the measurements off the inner wheel bearing surface. illustrated below: One is WMS. You're going to move the outer wheel bearing surface in towards the mounting flange about 5/8" and then cut the same amount (distance) of new threads on the spindle. although I have hears that WMS and possibly Dynatrac make them also . they replace top plastic bushing with a new bearing. and the only 35 spline external drive flanges available would be either the rare and long discontinued Spicer D70 parts. and therefore command les re-sale value . you have the pattern.com/knucklepage. and the chance of finding them in more remote regions .though this could of course be an advantage too.Limited lockout and drive flange availability .Com Bulletin Board who goes by the name of Welderboy. with no OEM parts. They are vintage '79 Well. Of course a driveshaft joint could break before some of this stuff depending on what size joints you are running. 900-1250 is the range for the '79 RC Kingpin model I paid $700 for mine but it was missing the calipers and one lockout. Remember this is not written in stone.pirate4x4.Extreme Four Wheel Drive Page 4 of 16 How do you replace the lower kingpin bearing? 1'st knock out the old race/cap with a punch from top to bottom.. put bearing cap/seal then slide knuckle back on and insert kingpin from bottom and bolt it in. then install the bearing race (I use brass punches for this). Who has the lowest price for 35 spline Dana 60 stub axles? Saw two sets yesterday on e bay. If running big inner with 35 spline (Dana 70) outer then the u-joint or 35 spline lock out will pop. When I was looking for one all the junkyards wanted $1500-2000 for a complete RC D60.15 Randy's: 66. Going price is in the $1200 . $1500 is the usual that I have seen depending on the condition When I was looking I found a number of 79 Ford D60s right at $1000. The Chevy/Dodge d60's fronts are definitely going for less.1 ring&pinion. I then had to pay $35 a piece for U-joints and $65 a piece for the 35 spline stub shafts I paid $50 for a complete set with worn out u-joints for my Ford front. but just observations from 8 years of running a 60 front In 18 years on an RC Ford 60 I have broken 3 steering knuckles. If running big style inners with 35 spline outers with 35 spline drive flanges then the u-joint will break. It all depends on how patient you are and how far you're willing to drive to get it In my junkyard searches I have found late model Ford D60 fronts range from 600-850. I found one for $1000 and happily jumped on the deal. What prices are you guys paying for Front Dana 60 parts / upgrades? Stock stubs should run about $55 per. When the stub breaks it will usually ruin the lockout and it can break the spindle (split the spindle) or cause the spindle to swell.00 (free shipping) Reider's 67. If running "big style" inners with the stock 30 spline stub axle then the stock 30 spline outer axleshaft or lock out will go. I found a complete 79 F250 with d60s for $900. Install the "tin" bearing cap 1'st.00 What breaks on D60 front? OK.. I wouldn't pay anymore than $1100. I found these prices for the 3-82-871 35 spline stubs: Local Spicer dealer: 76. I've seen them for less and more. 3. Ball-joint or King-pin price didn't really seem to change. 3 stock stubs. install bearing.Com . All NIB Spicer replacements I paid $100 for a used set of inners. and only $83 plus shipping for both of them What is the current market price for a 1979 Ford F350 front Dana 60.done. Hope this helps. I ve noticed 1500 is the average accepted price for a rc d60. I believe Essentially Offroad wants like $60 per stub. here is a run down of how things "usually "break: if running the taper-down 35 spline inners with stock 30 spline outers the inner will break where it tapers down or the stub will break at about the same time. 20 sets of http://www.00 TOR: 76. If the u-joint goes it will take out the ears on both axles usually.1500 range at yards.. any less is a 'deal' any more it better be in awesome shape.. steering included. U-joints about the same and my inners were about $225 for the pair. I picked up a pair of inners off eBay last night... you know you're gonna have to rebuild it. And the ring and pinion can be a victim if it is not set up properly to handle the abuse (I mean use) I have broken two 1480 joints which took out the inner and outer axles (broke ears) and I have broken a 35 spline Dana 70 rear axle shaft.pretty simple. they were in the 100 to 200 hundred range I got my spares from ORD. $65 each..80 Drivetrain Warehouse 64.Pirate4x4. I paid 1400 for a single wheel.html 8/22/2007 . 1000 for one that needs rebuilding Going price from the Salvage yards around here is about $900 to $1200 for a complete front Dana 60 hub to hub. Anything under a $1000 is a deal in my opinion. complete lockout to lockout.54 gears? 1250-1500 for one that s usable. Stock Spicer units for $78 each IIRC Randy's.com/tech/billavista/60_front/index2.1 inner long side. king pin rc d60.00 Drivetrain Direct: 79.... used. 4 yokes on 300M 35 spline stubs. timkeninfo. & a couple weeks ago I took out a stub. Should I tack-weld my Ujoint caps to the ears of the shafts? From my experience tack welding full snap rings or welding the cap completely as you have thought of already really seem to have very little benefit if any with the 60 front joints. from 1985 to 1991 will fit. http://www.html 8/22/2007 . Chevy King-pin. they cut .pirate4x4. I've busted one ujoint I have a friend that has busted 3 30 spline stubs in the front and 2 35 spline rear axles. you can go to www. every year now. 382s on the left. This might work but it doesn t leave much spline contact for your lockout. 2 inner. Also a couple sets of Spicer hub gears. Wagoner Machine Shop and Dynatrac sell 35 spline outer stub shafts for the Ford D60. What components do I need to change a stock 30 spline Ford Dana 60 king pin front (circa 1978) to 35 spline stub shafts? You can use Dodge or GM knuckles out.com and search for 382s and you will end up with 265 pages of applications! Here's a pic. To make up for the different length of the outers. 382a on the right. The GM / Dodge spindles are longer which is what you need to fit the 35 spline stubs. Knuckles out.600" the end of the shaft. Then the inner bearing race is replaced with part number 382S that spaces the hub and rotor out aprox. sell a Ford 35 spline outer kit. re-cut the snap-ting groove. I have broken several joints (spicer 5-332x joints) which also ruined the ears on the axleshafts in the form of stretching them. Also stripped splines in rotor. I shattered one cryoed 30 spline stub axle in an ARCA comp and a 35 spline inner at the yoke first run out with 35 outers in a situation that would have broken just about anything. I have broken one lockout. Every time I saw the stub axle break it always killed the lockout on the way out. I was twisting off the splines on my 30 spline stubs and just upgraded to 35 splines. You could also machine a spacer that spaces the spindle out from the knuckle.com/tech/billavista/60_front/index2. You get Chevy knuckle/spindle/hub/caliper/brakes and it is a bolt on swap. and 3 spindles. If you run the CTM joint the ears will shear right off and eject the joint out of the knuckle. It comes with the Warn lockouts and shafts for $475. All in 2 years The front HP 60 I haven't had in that long. 1/8". The 382s is the Timken number for the Dana60 carrier bearing race. I haven t seen it done but I have heard about guys using the 35 spline stubs and just cutting them down.Pirate4x4. spindle & hub. In the end the trunion is what I have always broke at the base of the cross which then destroyed the ears.Extreme Four Wheel Drive Page 5 of 16 wheel bearings.Com . completely tearing them off or breaking the side of them. If you need an application to quote to the counter-man. courtesy of Jeepin_NC of the 2 races side by side. You have to re-drill the GM spindle pattern to match the Ford knuckle if you use just the GM spindles and not the knuckles. but the taper for the tie rod is the next size smaller. 2 steering knuckles. Actually I had one joint explode the inner and outer ears without ripping them off so much that it wedged the innershaft into the outer axle and would still pull. Differential Engineering in FL. Do the Ford kingpin knuckles for the '86 to '92 (or about there) D-60's interchange with the '78-'79 Ford HP D-60? Ford Dana 60 knuckles. A good friend of mine has been taking out 2-3 stock stub axles. I have tried all the above options and still broke them in the same place. and relieve the splines at the end. The kit also uses Spicer Chevy length 35 spline outers. I clear 15" wheels.we have done it that way also. like $65 per stub and $210 or so for the lockouts. I have found that NOT running a snap ring causes less than great seal/spindle relationship *the butterfly seal* and in some axles I think it allows the shaft to walk out and that seems to have an ill effect on some brand lockouts. Note: Whichever method you choose.600 from the end and re-cut snap ring groove and relieve the spline at the end for the gear to slip past a little. He did my axles and he is making a bracket that will bolt to a 60 and allow you to use 78' Chevy 3/4 ton brake calipers and rotors.see chart above for details. Steve. Here is a pic. may not go before the lockout. only use the bolt pattern from the 1ton and only use the caliper retaining area from the 1/2 ton.. The lockout should go first but I have not had a failure yet! If you are running a GM 60 all you have to do is buy 2 Dana 70 stubs and the lockouts. hub and spindle are .000 lbs. Photo courtesy JB's 4x4 http://www. (I did) is use the 60 caliper bracket where it goes over the spindle. and that bracket won't allow clearance for the caliper "pins" to clear the rotor. you will need to run 35 spline drive flanges or lockout hub .pirate4x4. If you have those old taper down style inners then they will break before the joint. Inc.Pirate4x4. If you do cut it down then I don't know if you will run out of spline before the slug bottoms out or if it is enough engagement to be a real upgrade. 8.600" shorter than the Chevy. I will second what Steve said. I have busted a few of the u-joints while running 35 spline outers with horsepower and 44 inch tires.com/tech/billavista/60_front/index2. i. I know I have also run the Dana 60 without clip with drive slugs and have had good success. Wheelers/truck pullers here have been doing that for a long time and never an issue or failure caused by the modification that I have seen. How do I do a 3/4 ton disk brake conversion on a Dana 60 front? If you are sticking with 8 on 6. Do I have to run the snap-ring in the end of the stub shaft? On the Dana front the snap ring is very important on the stub axle. One other problem with cutting off the end is loosing the snap ring groove that holds the V-seal up tight against the back side of the spindle to keep out most of the water. tug of war on concrete.Com . If you are running the 35 spline outers with newer "big style" inners which don't taper down then usually the lock out will be the weak link (a fairly weak link at that). we have be doing this for five years.000 lbs. inc. Differential Eng. sled pull's. if it dose the "U" joint will be out of alignment with the upper and lower joint of the steering knuckle.html 8/22/2007 . Differential Eng. remove . spaced exactly where you want it. Then the u-joint is the weak link and breaks are much farther apart. "U" joint failures but not at the stub shaft. The stub must be retained from end play. it is only good for the small 5/6 lug rotor the 8 lug rotors are a bigger od. What are the pros and cons for upgrading to 35 spline outer stub shaft for a Dana60? I went to the 35 spline when I upgraded tire size to 42's! I was not worried when I only had 38's but I would not even think about anything other than 35 spline with any larger tires.e. This stubs and locking hubs have be through hell. But I still prefer using the snap rings.Extreme Four Wheel Drive Page 6 of 16 The Ford stub axle. Steve. and graft it to a Chevy 1/2 ton bracket to hold the smaller caliper.. with equally great results. The best set-up for myself is to run drive flanges with 35 spline outers combined with the "big style" inners that don't taper down.5 wheel pattern: The Dynatrac caliper bracket is of nearly no use to you. custom built in your garage! You might want to check with JB's 4x4. this alignment must be maintained when the steering knuckle is turned with the axle turning. What you can do. On this stub modification. but. 50. it keeps the dust boot pulled up to keep the mud and water out and protect the thrust washer. The axle can not move back. Cheap. but not much. grab 3ft long pipe wrench. Add a breaker bar and a little heat and no way the king pin will stay put.html 8/22/2007 . Rotors are too with the exception that the SRW wheel rotors have a larger hole in them for the lug studs' shoulder.. I had to take the front 3" of the outer caliper radius down about 1/8" to get them on. Here's the "special tool" that I use (several times a month for quite a few years now). of your wheels are and the backside of your hubs for the i. The D60 front calipers and brackets are very beefy. I know there is a special tool for this.5" backspacing.d. Just a little clearance grinding on the caliper is all you need.com/tech/billavista/60_front/index2. http://www. This will get the screw VERY hot. King pin removal the farmer way.. In fact what you have after you grind has way more material left than the 1/2tons stuff ever thought about having.. of your rotors.Com . Drill them to match and they will be identical. it is hardened and wont break like the nut and bolt trick.Pirate4x4.. but the wheel doesn't scrape anywhere. I want to run 15 wheels w/ 3.have a beer.5" medium grinding wheel. how much space do I need for the wheel. 2") acorn style lug nut for a 1/2" wheel stud that fits a 7/8" socket. pops them loose every time for me without heat. As you can see. heard the rubbing then pulled the wheel and broke out the grinder and shaved a little using a sanding disc to the metal backing of the brake pad that came outside the caliper. another remedy I've heard of is drilling a 1/4" hole in the bottom of the king pin screw. Get a long (approx. I think it's because it has a lot to do with not only exactly what type of brakes and calipers are used and how much backspacing (bs) the wheel has.5 backspacing 15's will fit with little or no grinding on the dual piston calipers You can grind Chevy calipers and fit 15 inch wheels... but don't have a clue where to get one at. Took about an hour and 25% of a 4. and then filling the hole with weld.200 or whatever your i.. Book calls for 500-600 ft/lbs. I tried this twice.pirate4x4.. When I say "little".. How much you grind depends on what offset wheels you run Steel beadlocks 3 inch backspacing and mine fits over 8 lug 92 F350 rotor's and calipers with a little grinding to the outside . What s the difference between Dana 60 front SRW and DRW brakes? Caliper brackets are the same. 1 min later bolted the wheel back on and spun. slip it in the king pin and slip a socket over it. and 3/4 ton 8 lug rotors both front and rear. I had to grind A LOT! Both sides look like the pics below. How do I remove the kingpin? Some people made a tool with 7/8" nuts welded to a bolt to remove the kingpin. It has two piston calipers had 16. If this doesn t work.. Here is one side almost finished. Drag torch to project. and a 1/2" breaker bar the second time..maybe 20 mins of grinding on each side. Put a lot of pressure on it and smack the axle with a brass hammer right next to the threads a few times. I put the wheel on then spun it.Extreme Four Wheel Drive Page 7 of 16 On a Ford 60 front all the Dana 44 stuff from a Ford will bolt onto the Ford 60. Is getting a pebble caught between the caliper and the wheels and destroying my wheel a real danger? Just following up with some pic like someone asked for. I am running a front D60 with 15".but what about installing it.d. the material removed is not going to pose a problem in the safety dept.5 hours today grinding my d60 calipers to fit my new beadlocks! And I only got one side done!!!!! This is crazy! My question is. Photos courtesy Patooyee. VA for $25. Right now I have very little. broke the bolt the first time.cut 1/3 of king pin away forming a flat side. Okay..remove king pin.5" wheels. then re-drill the bolt pattern of the hub. Is there a caliper that will bolt up (single piston is ok) or am I going to have to fab some mounts? If you don t mind running a 2. I had to do a little more grinding after this.. I run 15x10 wheels. I just bought a 7/8" allen wrench from Potomac Steel in Springfield. How do I mount a 15in. wheel on a front D60? Note: This one of those topics that get a LOT of different opinions and info on. with 3" bs. I'm sure one of those ways will remove the pin. I spent 2.my back spacing is 3 1/4 and had to grind a little but wasn t that hard. the way these calipers/pads are there is no way to grind enough to fit these wheels. The allen wrench I bought is made by Chesco. so even 2 rigs with the same brakes and bs may require different amounts of grinding on the calipers. If you're set on removing it. it is made in the USA and is better than a foot long. If you are going to a 5 or 6 lug bolt pattern: You will have to machine your wheel hubs outside to 4. No rubbing! Went to the other side and did the same. I Did the same thing and ran a 8" wheel I've got a D60 front that I just put 15x8 8 lug wheels with 4" back spacing on. but also the design profile of the rim. I have Ford Dual Piston calipers and run 15x10 3 inch backspacing with minimal grinding I recently bought a D60 from an F250 plow truck (79 I think). I've heard that it's often necessary to apply LOTS of heat to the knuckle with a rosebud.. I used a mix of Dana 60 parts and Dana 44 parts to get it done.5 this fall. Most of the grinding was on the pads and only used a soft wheel on the calipers. I used the calipers from an '82 front instead of '79 (the year of my axle) because they are designed different and there is a lot less to grind luckily someone told me this. These calipers can be seen on TTB Fords with dual piston calipers. Ford half ton. my question is how do you fit the 82's on the 79' caliper bracket? I noticed they were the right size to fit the slide groves but there were some cast nipples on the 82' that would not allow the caliper to fit. First side took about 2hrs. 4" backspacing. FL I went to the store today and compared an 82' Dana 60 caliper to my 79' calipers.Extreme Four Wheel Drive Page 8 of 16 I have less than a 1/16" clearance and have had no trouble at all. Photo courtesy MR4WD Ford (dual piston) calipers require much more grinding than GM.. it just takes time to find the spots where it's touching and rubbing.5" BS. Mines a 92 and uses little wedges with rubber in the center.5"backspacing and very little grinding..pirate4x4.maybe 10 mins on each side. since I did not want to grind any more than I had to one of the wheels even rubbed a little and still no trouble. http://www. One uses the little wedges that are held on with a bolt 78/79 and maybe a few years in the 80's.net/russhuffman/grinding/calipers.members.cox. Then you just have to make a caliper bracket to fit (see 3/4 ton brake conversion above). The '79 has a large lip/edge along the whole outer part of the caliper. No problems thus far with anything getting trapped. no grinding My 15's with 2. all afternoon for one side! I have the Ford dual piston calipers. the '82 calipers I bought do not have this lip.Com . 3.5 back spacing and didn t have to grind much at all.html 8/22/2007 .) With these '82 Ford calipers there really isn't that much to grind.. I was originally told about this switch by Steve at "Differential Engineering" in Winter Haven. most people do not consider them a potential for 15" wheels unless you run VERY small backspacing.Here s my article: http://www. and just chop-chopped the hell out of it. 2. GM calipers. All parts are Ford 1979 Dana 60. beadlocked. I have about 3. In fact.5" BS. They were still rubbing. cleaned up with a grinding wheel.Pirate4x4. I say there is no danger at all with running little clearance.. Go with it 2 inch backspacing. but they'll self-clearance 15x16! 3. In fact. and then redrill the flanges. About 1/8" space between the wheel and the caliper. I've got 4" of BS and I ground it just enough to clear. I Ground mine for the same reason.5 bolt pattern? The way most people do this is to use the D60 hubs and turn them down to fit through the 5 lug rims. I converted a D60 over to 5 on 5.html '79 Ford RC Dana 60 with 79 Ford dual piston calipers.. Now that I have one done I think I can probably do the other side in about 10 minutes. and then the newest style that is held on with 2 bolts. It is very close.. . or Chevy half ton. turn the backsides down to fit the 5 lug rotors.com/tech/billavista/60_front/index2. It is only raised at the ends and that receives a bit of grinding to fit.5" backspacing fit on my RC D60 out of a 92 F350 with NO grinding at all. How do I convert a Front Dana 60 to 5x5. I used a cut-off wheel on the grinder. 3 3/4" bs and it took the whole afternoon. No problems yet.. Second side took 30 minutes. do you need to grind these down and what other issues would I run into putting these on my 79' I think Ford used 3 different mounting setups for the twin piston calipers. 1999-newer Ford Super Duties are 8x170mm hole spacing with 14x2 metric lug bolts/nuts As for the wheels themselves. they may be 1/2". etc. same 30 spline as the 60 shaft.5... so the hub backside may not need to be turned down.Extreme Four Wheel Drive Page 9 of 16 Here s the parts list: Dana 60 spindle Dana 60 hub machined down and re-drilled to 5 on 5. or not as much . What's the deal with the Ford solid-axle Dana 50? If this is a Ford Super Duty style 50 they are ball joint. Are all truck 8 lug patterns the same? The Big Three (Ford.. I had a tracing of Dynatrac's bracket. I think Dodge is the same as Chevy. Weld spiders to sides and sides to spiders on both sides and then take a rectangle piece of metal 3/8 thick or even thicker and drop it in on both sides and then weld it all the way around. the Chevy rim will not interchange between Dodge and Chevy.photopoint. But they work awesome so worth the extra money. OD of the hub turned down.com/j/Albu. Well worth the extra over standard calipers in my opinion. a 1/2" thick spacer/adaptor to bolt to the 60 knuckle and bolt the spindle to. Sunray will do this conversion with your parts.5" BP too? I don't see why not. bore out a big bearing D44 spindle till the bearing fits. They are running no spindle bearings. no need for high tensile or heating it up. its the one they are using in their rear full float conversions. the Howe calipers were around $220 for the set. they use the 60 size ujoints. never seen it though.5 Dana 44 rotor (F-150/Bronco) center bore machined out to fit on the Dana 60 hub Machined brake caliper bracket out of 1/2 steel. but came out great and pretty cheap. 9/16". re-drilled. but the pin can break when it is done like this on smaller axles. and slid them out 1/8" or so for more knuckle clearance.. The brakes cost substantially more. I prefer not to weld to the casting of the carrier. and the only thing the people running it have broken is a hub. A little grinding on the knuckle. 14 bolt's. Start as far in as ya can then work your way out. I've heard of this set-up before. I'll leave it to you to sort through it and decide what you think is best. let it dry then lay down some type of welding prep spray to minimize http://www. I had a local metal shop flame cut the caliper brackets from 3/8" plate (7/16 would be better). I used GM / FSJ 2 bolt calipers. Everyone I've seen welded (we're poor up here in the hills so that's a lot) we just weld the side gears to the carrier and then fill between the spiders and side gears where they mesh. I did the same conversion to 5 lug on my Hybrid Dana6/Ford9" front.pirate4x4.Com . I tack welded the stud to keep it straight. but it all goes together. Dodge and Ford rims have the bigger holes to fit over the rear Dana axles.88 at this time but the locker choices are slim still.. How do I weld up my diff for a "Lincoln locker"? This is one of those 'ask 100 people. back side of the hub matched to F150 rotors. No problem with 15" wheels. helps to heat (to get the gear oil out) then sand blast then clean really well before. and weld everywhere they make contact.5" if you wanted to use some wheels you might already have. but if you have a buddy who is a machinist you could probable replicate for a lot less. you do end up trimming a little off the spline end of the outer shaft. A Ford has a slightly larger center-hole. I hate to say what I paid for the caliper bracket. get 100 different opinions" kind of questions. Take the ring gear off clean the carrier with brake parts cleaner or something similar. and fits in the 44 hub. Transferred the spindle bolt pattern.. So. so a Ford rim will fit everything.com/tech/billavista/60_front/index2. Never has caused problems as of yet! 6 years going on 7. BTW.the new carriers are about $50-$75 new. 70's. Took a lot of figuring and measuring. Basically flat but machined to allow 1/4" clearance for brake pads. I've hammered mine hard and still no cracks. they have a 9" ring gear so 44 stuff does not work.. Just weld the spiders to the case and also to each other. but the Chevy rim will NOT fit on a Ford axle. where the Chevy rim hole is smaller since the GM 14Bolt rear axle hub is smaller in dia. Talked extensively with a guy in WA that makes a kit like that but wants $900 for it!! What he does is make a spacer. backing plate.5" until the new Ford super duties. 1 hole is almost 1/2 way into one of the old 8 lug locations. and caliper. and use a 6 lug 3/4 ton Chevy rotor. Use a MIG so you can get further in to start. I like to get some real beef in there. The 14bolt carrier remains even if you buy a locker and they are $250 new. rotor.html 8/22/2007 . cause its to long. and a lockout can be bought from Warn.. Dodge) are the same 8 on 6. Around $150. 5/8".=1&showall=true I used a 60 hub. this may be ok on big axles like d60's. GM.Pirate4x4. all my side and spider gears are welded to each other and the carrier. Some pics: http://albums. a Chevy wheel has a smaller center-hole in the rim. $800 Another method is a Chevy 60 knuckle... on mid 80's thru mid 90's. but I know people who have done it without problems. Incorporated Dana 60 spindle pattern and Howe twin piston Chevy calipers. but really nothing too sophisticated. and they do have the 8 on 170mm pattern so you would need to change that to 6. also the hole in the center of the Chevy rotor is bigger. The have gears for them up to 4. then you use a 44 hub. Well I can show you a way that has been tried and tested on front 44s and for 60s or any thing that you don't have to go in and pop out c-clips. Just in case they go locker later. if you just weld the side gears and spider gears together all your force is on the pin.. Personally. The first time I helped a buddy weld one up. I have a good connection for machine work. Gears to gears and gears to carrier is the way I have seen hold.weld the piss outta it. F-150 wheel studs Getting the hub and brakes machined and re-drilled was cheap. Knuckle needed slight grinding to allow free caliper clearance. a Chevy 44 spindle. Not sure if that s the right way to do it but that s what he told me! You guys think that this would work with a 6 on 5. adapts D60 lockout hub internals into a D44 lock-out. In the old days (before Everybody had a MIG) we would throw some nuts and bolts in the weld area and burn them in for additional filler. These were needed for clearance at piston and knuckle. we welded it to the carrier and ended up having to reset the gears cuz the carrier musta expanded or something. If you have a DANA axle. a 60 outer shaft.this is why people are only welding the spiders on the 14bolt. you just re-drill the hub to 6 on 5. The all used different size studs depending on year and application. it'll work fine. Got about 10 years on mine. I have a taco rear in my '85 that I welded.. ~90 amps and go to town. I'm not an experienced welder by far.. but when I pulled my diff cover off to fix a hole. My method is to clean very well.Extreme Four Wheel Drive Page 10 of 16 splatter be sure to weld it HOT but not to the point it distorts the splines on the inside I think the best way to do it is to just weld the spider gears together it doesn't matter if the welds crack the spider gears won't spin. Use 6011 rods. I used 7018. Still locked up for a day or two..a big Miller power source with a wire feeder mounted on top of it. strong and won't break very easy. I have a v8 and run it hard. Also. I have welded three diffs with it now and it has worked. I have tried 7018 also and I know it works too.Com . I used 210 miller MIG and it worked great. I use E7018 I have been told to use 308 stainless. I just took it out after a summer of mud bogs and there are still no cracks anywhere.com/tech/billavista/60_front/index2. multiple passes. I used too big of a rod and too much heat and I melted the gears instead of welding them. Here is the recipe for welded thirds: remove third from axel clean with carb cleaner really well preheat weld the spider gears together and to the carrier use 7018. I've heard 6011's work real well. I've gone through 4 Birf's and it's still good.000 PSI. And like most everyone has mentioned cleanliness is next to godliness when it comes to welding.. Lo Hi is made for welding high carbon steel without cracking. I didn't even cover the splines and it was fine. Isn't 7018 (mild steel) the wrong type of metal to be using on gears (high carbon steel)? would something like nickel rod with a little more give to it work better. low spatter! change sides frequently to avoid cracking anything. this way you don't weaken the carrier which is the part that breaks. 3rd gear burnouts etc. used the 7018. It sounds like what you are saying is that if you get them welded good they are just as good as a spool? I welded mine about a month ago. or just TIG it up completely with some mild steel rod. it has to double as my muscle car. It is a bad idea to weld it in the vehicle but it is a much worse idea to weld it in the vehicle with the ground clamp attached to the housing so that the current has to be conducted through the bearings so clamp it to a ring gear bolt or something. As far as spatter goes I think 7018 leaves a lot less spatter than MIG. just weld the gears. multiple passes. I peeled out on the dry pavement and it hasn't broke yet. and it worked fine BUT right after I welded where the side gears engage the spider gears each weld had a crack? What am I doing wrong? I routed out the cracks ( they weren't deep) and Fused them back together with the TIG. 7018. but my confidence is gone now until I figure out what I was doing wrong or what was set wrong with the machine . I also welded the side gears to the carrier. 7018 it. The carrier is cast steel and you will weaken it by welding on it unless you do a stress relief after. so I decided to try the MIG. Try to make the beads convex. especially below the surface. I've got almost a year of hard wheelin' on mine and about a month on Jack's. Otherwise it is one piece now. also if you can lay a wider bead with a little less penetration the bead is less likely to crack. but now I am back to an open diff. it hasn't broke yet. It seems to work much better.html 8/22/2007 . DO a few passes. I bathed the diff in solvent. Just doing the spider gears puts all your faith into the x-pin.daily driver. No different than a mini spool. I cleaned out the chunks and put it back together.Pirate4x4. I had a friend (professional welder for 7 yrs) weld one diff for me with 7018 and when I took it out months later the welds had cracks in them.. maybe I should change to mild steel wire? any ideas appreciated I have MIG welded stainless to mild steel and had it crack just like you are saying. 6011 is a very poor choice for high carbon steel. I just laid weld every where. The stainless rod is used because it is less likely to crack. If I had easy access to a TIG and didn't pay for the argon I would use that.. Simple. Just used a screw driver and popped the splatter off. I welded mine (front) with 7018 and Jack A's rear with a Millermatic 210. I welded mine all together and kept spraying everything with the anti spatter and I ended up with very clean welds and almost no spatter. 7018. I used 308 stainless to arc weld my diff with no preheat and it did not crack when I welded it. pre-heat. enjoy. That is the reason you get a spool over welding. so with what I have in my garage I would use that. I welded my rear diff last week for the jambo. I am going to try it again with 6011 rod. let it cool naturally install Lincoln locker and have a blast! if you use some anti spatter welding spray you can probably leave the ring gear on. I saw that all my welds had broken. and then heated it with a torch to burn off the residual oil..000 PSI rod instead of 60. that is if you can control where you put the rod. Most of the Lincolns that I've seen break were not welded to the case. just weld the gears) and to my knowledge none have failed. concave beads are more likely to crack. Cover them up with 6013 and grind them down clean. it worked fine but an awfully small bead. or maybe stainless? and no. What kind of rod did you use the first time? I'd use 7018 since its a 70. use some regular mild steel wire. and multiple passes on everything. I used the TIG some. pre-heat.pirate4x4. I have probably done 10 rear ends this way ( clean very well. If I did it again I would have put a stick in the spines and taken off the ring gear. Held up through the jambo. that stuff is sweet! spray it on the ring gear and the axle shaft splines in the carrier! good luck. Also watch the interpass temperature. In my opinion welding to the case makes the unit stronger as a whole.carbon / alloy steel 6011 is for rough work w/ crap metal that is dirty (aka farmer rod) clean it. I have been able to weld with stainless without preheating and not have the welds crack when it cools http://www. don't catch yourself on fire! 7018 is for hi. using 308 stainless wire. but all of the steering is maintained. the words are all theirs except the last line in orange which is mine. This design allows for flex and deformation inside the ear which lets the u-joint cap turn and eventually fail. I think it looks very cool. All of this extra material inside the knuckle does require some custom machining. In comparison to a standard stub shaft it is easy to see how much more material is placed around the u-joint.com/tech/billavista/60_front/index2. and how the U-bolt system is far more reliable than the 1/2 moon or even full retaining clips. http://www.Com . The Dana 60 and our 1 ton 609 both use a 1480 series u-joint.Pirate4x4. Contact them for details. The pics are all theirs.Extreme Four Wheel Drive Page 11 of 16 Sunray Engineering 60 Here's some info and pics from Sunray Engineering on their "Sun 60" axle upgrade.html 8/22/2007 . One of the major down falls of the front axle and stub shafts is the ear design. The Sun 60 axle shaft set up is designed to defeat these stresses and virtually eliminate breakage.pirate4x4. Seen here in a Dana 60 knuckle the Sun 60 is a tight fit. The axle shafts are made from 4340 and are double 35 splined. The 1 ton front ends have shown to be one of the most popular swaps for hard core wheelers. The yokes are made from A572. which is far superior to stock yoke material. The spindle is also custom to allow extra clearance for the yoke. 95 $14. and the Sun60 yoke on the left.5" X 35 SPLINE INNER AXLE (GM) **17.59 $8.07" LONG AXLE U-JOINT SPINDLE/WITH SEAL INNER WHEEL BRG KIT OUTER BRG KIT STEERING ARM (Includes 4 studs.00 $159.95 $109.99 *35 SPLINE EARLY FRONT KINGPIN STYLE AXLE .html 8/22/2007 .00 $1.59 each $7. Dana 60 parts lists from selected manufacturers / suppliers: PartsMike D60 parts Part # DAN706395X DAN620132 DAN37307 DAN37300 DAN41886 DAN37302 DAN3-82871 DAN907967-5 DAN907957-6 DAN5-332X DAN700013 DAN706411X DAN706074X PM6006 BRC1001 T60TKI PM77359 PM77359-5 PM77359-6 Description KING PIN BEARING KIT 4 BOLT SPRING CAP GASKET SPRING PLASTIC BUSHING KING PIN 1.29 $2.39 $2.00 $59.5" X 35 SPLINE INNER AXLE (GM) **35.95 $99.95 $89.00 $189.com/tech/billavista/60_front/index2.59 $8. nuts and spring spacer plug) DRAGLINK NEW 60 AXLE "C"s (pair) 60 SPINDLE STUD AND NUT 60 SPINDLE STUD AND NUT KIT (5 studs and nuts) 60 SPINDLE STUD AND NUT KIT (6 studs and nuts) Price $25.95 $8.Pirate4x4.Extreme Four Wheel Drive Page 12 of 16 Here's a pic of the stock D60 yoke on the right.95 $0.00 $99.GM.00 $28.5" X 35 SPLINE OUTER AXLE *12.Com . DODGE FORD REQUIRES MODIFICATION TO BRAKES TO USE 35 SPLINE OUTER AXLE **INNER AXLE IS FULL DIAMETER OTHER LENGTHS AVAILABLE .00 $99.67" LONG RH 1.pirate4x4.00" LONG LH 1.MEASURED FROM CENTER OF U-JOINT TO END OF SPLINE Drive Train Specialists D60 parts list: Product Name Description Manufacture Price http://www. 10 DOWN DANA 60 OPEN DIFFERENTIAL EMPTY 4.10 DOWN DANA 60 OPEN LOADED 4.17 RATIO-PRO GEAR DANA 60 6.82 80.10-DN DANA 60 KING PIN KIT DANA 60 INST KIT NO BEARINGS DANA 60 CRUSH SLEEVE DANA 60 COVER KIT DANA 60 COVER ALUMINUM GIRDLE COVER DANA 60 COVER DANA 60 CASE KIT-4. 32 SPLINE 4.13 RATIO-COMP GEAR DANA 60 5.10 DOWN W/ABS DANA 60 OPEN DIFFERENTIAL 4.88 362. DANA 60 T/L CLUTCHES DANA 60 T/L CASE-4.10 DN DANA 60 CASE ASSEM.4 261.13 RATIO REVERSE CUT DANA 60 5.9 70.13 RATIO-REVERSE THICK GEAR-FITS 4.9 98.18 343.10 & DOWN FOR ABS DANA 60 OPEN DIFFERENTIAL 35 SPLINE DANA 60 OPEN CASE DANA 60 OPEN 32SPL 4.5 241.38 RATIO-THIN DANA 60 5.6 168 12.52 91.5 229.88 RATIO REVERSE CUT FITS 4.88 343.25 381.07 244.410DOWN ABS 32 SPLINE DANA 60 T/L SPYDER KIT 32 SPL.17 RATIO DANA 60 7.com/tech/billavista/60_front/index2.02 229.13 RATIO-THIN DANA 60 5.88 327.1 407.14 62.54 93.pirate4x4.48 34.88 RATIO REVERSE CUT DANA 60 4.88 RATIO-REVERSE THICK GEAR-FITS 4.17 RATIO DANA 60 5.18 313.36 92.10 DN DANA 60 CASE ASSY 4.2 296 400 248 89.78 156.Pirate4x4.34 66.64 206.76 123.72 155 41.46 84.78 91.88 RATIO-PRO GEAR DANA 60 4.Com .56 UP DIFF SPICER SPICER SPICER SPICER SPICER SPICER SPICER SPICER SPICER SPICER SPICER SPICER SPICER SPICER SPICER SPICER SPICER SPICER SPICER SPICER DTS DTS SPICER SPICER DTS SPICER SPICER SPICER SPICER SPICER DTS SPICER SPICER SPICER RICHMOND RICHMOND SPICER SPICER RICHMOND RICHMOND US GEAR RICHMOND DTS RICHMOND US GEAR PRECISION GEAR PRECISION GEAR PRECISION GEAR SPICER US GEAR RICHMOND DTS RICHMOND PRECISION GEAR SPICER 64.10 DOWN DANA 60 OPEN LOADED DIFF 32 SPLINE 4.10 DN CASE DANA 60 4.10 & DOWN W/ ABS DANA 60 OPEN EMPTY DIFF 35 SPLINE 4.62 229.7 79.13 RATIO-PRO GEAR DANA 60 5.62 316.88 RATIO-THIN DANA 60 4.86 RATIO DANA 60 5.79 310.72 340.5 4 13.10 AND DOWN DANA 60 BEARING KIT DANA 60 7290 YOKE DANA 60 7.17 RATIO DANA 60 6.28 231.56 UP DANA 60 CASE ASSY KIT-4.13 RATIO DANA 60 4:10 DOWN ANTI-LOCK DANA 60 4.92 248.Extreme Four Wheel Drive Page 13 of 16 SP3-4-5731X SP2-4-3801-1X SP3-4-11891-1X SP707388X SP707434X SP707083X SP706039X SP707144X SP707164X SP706702X SP706043X SP707214-1X SP707387-1X SP707211X SP707212-1X SP708011 SP708010 SP706180X SP707212X SP74950X DTSD60-KP/KIT IK83-2034 SP45658 SP707108X TA1812 SP42799-1 SP706041X SP706036X SP706040X SP707387X IK83-1034 SP3-4-8051X SP706033-8X SP26756-5X DTS79-0037-1 DTS79-0041-1 SP706033-7X SP706033-6X DTS69-0146-1 DTS79-0013-1 DTS05-897513 DTS69-0057-1 DTSD60-513R DTS79-0025-1 DTS05-997513 PG60D/513R PG60D/513P PG60D/513 SP707214X DTS05-897488 DTS69-0054-1 DTSD60-488R DTS79-0068-1 PG60D/488R SP707475-4X DANA 60 YOKE 1350 DANA 60 YOKE 1310 SERIES STRAP STYLE DANA 60 YOKE DANA 60 T\L CASE ASS.html 8/22/2007 .38 210.50 RATIO-PRO GEAR DANA 60 6.38 RATIO-PRO GEAR DANA 60 5.16 http://www.81 244.88 RATIO-THIN DANA 60 4.13 RATIO PRO GEAR DANA 60 5.13 RATIO-THIN DANA 60 5.74 217.18 121.7 296 326.10 DN CASE DANA 60 5.38 213.56 UP DANA 60 T/L CASE W/ABS DANA 60 T/L CASE DANA 60 SPYDER KIT-35 SPLINE DANA 60 SPYDER KIT DANA 60 OPEN/EMPTY DIFF 32 SPLINE 4.06 300 67.58 115.32 204. 56 RATIO DANA 60 4.73 RATIO DANA 60 3. CRUSH COLLAR DANA 60 3.10 NUMERICALLY LOWER DANA 60 35 SPLINE SEMI FLOAT 4.2 293.7 200 170 200 200 200 302.10 DISCONNECT FRONT CRUSH SLEEVE STYLE DANA 60 4.75 248 229.58 309.73 RATIO DANA 60 3.73 RATIO DANA 60 3.10 & DOWN CASE ASSM DANA 60 4.07 216.14 335.75 317.73 RATIO DANA 60 3.54 DISCONNECT FRONT CRUSH SLEEVE STYLE DANA 60 40 SPLINE SPOOL 4.56 RATIO DANA 60 4.54 RATIO DANA 60 3.30 RATIO DANA 60 4.73 RATIO DANA 60 3.3 234.88 RATIO DANA 60 4.56 RATIO DANA 60 4.Pirate4x4.56 RATIO-THIN DANA 60 4.34 237.30 RATIO 4.54 FORD ONLY DANA 60 3.10 RATIO DANA 60 4.94 200 400 216.56 NUMERICALLY HIGHER AIR LOCKER SPICER PRECISION GEAR SPICER US GEAR RICHMOND DTS RICHMOND PRECISION GEAR SPICER SPICER PRECISION GEAR PRECISION GEAR US GEAR PRECISION GEAR RICHMOND US GEAR SPICER SPICER RICHMOND PRECISION GEAR DTS SPICER SPICER SPICER SPICER SPICER SPICER PRECISION GEAR SPICER SPICER SPICER SPICER SPICER SPICER SPICER SPICER SPICER SPICER SPICER RICHMOND PRECISION GEAR DTS SPICER SPICER SPICER SPICER SPICER SPICER RICHMOND PRECISION GEAR SPICER SPICER STRANGE SPICER ARB 294.10 RATIO DANA 60 4.88 348.54 RATIO-REVERSE DANA 60 3.56 RATIO-PRO GEAR DANA 60 4.30 RATIO PRO GEAR DANA 60 4.73 RATIO SEMI-FLOAT DANA 60 3.56 RATIO-REVERSE 4.96 362.10 RATIO-REVERSE CUT CRUSH SLEEVE DESIGN DANA 60 4.10 RATIO-PRO GEAR DANA 60 4.12 297.10 RATIO DANA 60 4.62 743.10-DN CARRIER DANA 60 4.3 291.73 RATIO DANA 60 3.2 303.7 296 299.10 RATIO DANA 60 4.54 RATIO DANA 60 3.54 RATIO-SEMI FLOAT DANA 60 3.88 362.07 244.07 200 170 296.56 UP OPEN ASSM DANA 60 4.56 & UP CARRIER ONLY DANA 60 4.8 215.94 294.73 RATIO FORD ONLY DANA 60 3.Com .10 FORD ONLY DANA 60 4.88 RATIO DANA 60 4.75 229.2 225 336.pirate4x4.10 RATIO DANA 60 4.10 RATIO CRUSH SLEEVE DESIGN DANA 60 4.10 RATIO-THIN GEAR 4.68 200 205.html 8/22/2007 .07 200 309.10 RATIO DANA 60 4.10 RATIO CRUSH SLEEVE DESIGN ONLY!!!! DANA 60 4.com/tech/billavista/60_front/index2.92 357.10 RATIO-REVERSE DANA 60 4.62 311.14 237 229.Extreme Four Wheel Drive Page 14 of 16 SP706033-5X PG60D/488 SP706037X DTS05-897456 DTS69-0053-1 DTSD60-456R DTS79-0077-1 PG60D/456R SP706033-4X SP25127-5X PG60D/456 PG60D/430P DTS05-897430 PG60D/430 DTS69-0052-1 DTS05-897410 SP707475-2X SP700020-2 DTS79-0011-1 PG60D/410R PR24807-5X SP75248-5X SP76047-5X SP75311-5X SP706834-4X SP706033-3X SP24807-5X PG60D/410 SP707430-3X SP708009-2 SP707213X SP708021-1 SP707345-2X SP706834-3X SP707430-2X SP76086-5X SP707424-2X SP706033-2X SP25538-5X DTS49-0130-1 PG60D/373 PR25538-5X SP706834-2X SP706807-2X SP700020-1 SP75185-5X SP706033-1X SP24813-5X DTS49-0129-1 PG60D/354 SP707430-1X SP708009-1 SED-1546 SP707090-4X ARBRD42 DANA 60 4.54 RATIO CRUSH SLEEVE DESIGN DANA 60 3.54 RATIO-SEMI FLOAT DANA 60 3.94 200 309.10 RATIO REVERSE CUT DANA 60 4.64 216.09 NEW STYLE DODGE DISC.56 RATIO-THIN DANA 60 4.54 RATIO DANA 60 3.12 http://www.76 401.56 RATIO REVERSE CUT DANA 60 4.26 237.54 RATIO DANA 60 3.72 229.88 294.76 290.10 RATIO-THIN DANA 60 4.41 562.73 RATIO DANA 60 3.10 DN CASE DANA 60 4.09 RATIO DANA 60 4.56 NUMERICALLY HIGHER DANA 60 35 SPLINE TRAC LOC 4.46 358. Nut.56 NUMERICALLY HIGHER NON-ABS DANA 60 30 SPLINE POWER LOCK 4.36 $55. Loaded 4. Loaded 3.56 NUMERICALLY HIGHER DETROIT LOCKER DANA 60 35 SPLINE 4.com Part Number 706040-X 706041-X 706039-X 706036-X 706037-X 706840-X 706182X 42449 SA35-2034 SA25-2034 706047X Price $90.12 486.56 NUMERICALLY HIGHER DANA 60 35 SPLINE 'I PIECE CASE DANA 60 35 SPLINE FITS TRAC-LOC DIFFERENTIAL DANA 60 35 SPLINE SPOOL 4.10 Case.38 $190.html 8/22/2007 .87 546.33 $192.33 .46 686.17 Drivetrain.98 $190.17 Case.10 NUMERICALLY LOWER NON-ABS DANA 60 30 SPLINE NON C-CLIP FITS TRAC-LOC DIFFERENTIAL DANA 60 30 SPLINE NON C-CLIP FITS OPEN DIFFERENTIAL DANA 60 30 SPLINE C-CLIP FITS TRAC-LOC DIFFERENTIAL DANA 60 30 SPLINE C-CLIP FITS OPEN DIFFERENTIAL DANA 60 30 SPLINE 4.4.35 Differential Parts Description Case.56 NUMERICALLY HIGHER DETROIT LOCKER DANA 60 16 SPLINE 4.56 NUMERICALLY HIGHER DETROIT LOCKER DANA 60 30 SPLINE 4.7.10 NUMERICALLY LOWER DANA 60 30 SPLINE POWER LOCK 4.7.56 NUMERICALLY HIGHER W/ABS DANA 60 30 SPLINE POWER LOCK 4.56 .93 $115.56 NUMERICALLY HIGHER W/ABS DANA 60 35 SPLINE SEMI FLOAT 4.35 519. Bearing (Outer & Inner) Bearing/Overhaul Kit Installation Kit (no bearings) Carrier Bearing http://www.10 NUMERICALLY LOWER NON-ABS DANA 60 35 SPLINE FITS OPEN DIFF DANA 60 35 SPLINE 4.4.10 Case.56 NUMERICALLY HIGHER POSI DANA 60 35 SPLINE 4.56 NUMERICALLY HIGHER DANA 60 35 SPLINE 4.Pirate4x4.10 Case.98 $136.49 $36.7.4.56 NUMERICALLY HIGHER AIR LOCKER DANA 60 35 SPLINE TRAC LOC POSI DANA 60 32 SPLINE FULL FLOAT 4.8 525.10 NUMERICALLY LOWER MACHINED FOR C-CLIP DANA 60 30 SPLINE 4.10 NUMERICALLY LOWER AIR LOCKER DANA 60 35 SPLINE POWER LOC 4. Empty 4.94 630 525.10 NUMERICALLY LOWER AIR LOCKER DANA 60 16 SPLINE 4.30 NUMERICALLY LOWER DANA 60 35 SPLINE 4.54 526.53 499.53 499.87 369.67 $50. Loaded 3.56 NUMERICALLY HIGHER AIR LOCKER DANA 60 35 SPLINE SPOOL 4. Empty 3.56 NUMERICALLY HIGHER AIR LOCKER DANA 60 30 SPLINE 4.10 NUMERICALLY LOWER DETROIT LOCKER DANA 60 32 SPLINE FULL FLOAT 4.02 546.12 377.8 525.pirate4x4.56 .com/tech/billavista/60_front/index2.10 NUMERICALLY LOWER W/ABS DANA 60 35 SPLINE POWER LOC 4.7 262.33 . Loaded 4.Extreme Four Wheel Drive Page 15 of 16 PG60D/PLCAH35ABS ARBRD43 PG60D/PLCAH35 PG60D/PLCAL35ABS PG60D/PLCAL35 PTX95-0460-3500 ARBRD36 SP707097-4X LR2620 PTX95-0460-3520 SED-1548 TT225S-29A AU544821 ARBRD35 SED-1547 TT225S-29B ARBRD95 MG097035 ARBRD96 PTX95-0460-3220 PTX95-0460-3200 SP74951X SP708013 PG60D/PLCAH30ABS PG60D/PLCAH30 PG60D/PLCAL30ABS PG60D/PLCAL30 PTX95-0460-3020 PTX95-0460-3000 PTX95-0460-3025 PTX95-0460-3005 SP707097X SP24607X LR2610 TT225S-19A ARBRD21 TT225S-19B ARBRD22 TT225S-12A TT225S-12C DANA 60 35 SPLINE POWER LOC 4.Com .38 $213.10 NUMERICALLY LOWER DETROIT LOCKER DANA 60 30 SPLINE 4.10 NUMERICALLY LOWER W/ABS DANA 60 30 SPLINE POWER LOCK 4.12 342 743.56 .10 NUMERICALLY LOWER DETROIT LOCKER PRECISION GEAR ARB PRECISION GEAR PRECISION GEAR PRECISION GEAR POWER TRAXX ARB SPICER LOC RITE POWER TRAXX STRANGE DYNEER AUBURN ARB STRANGE DYNEER ARB MOTIVE GEAR ARB POWER TRAXX POWER TRAXX SPICER SPICER PRECISION GEAR PRECISION GEAR PRECISION GEAR PRECISION GEAR POWER TRAXX POWER TRAXX POWER TRAXX POWER TRAXX SPICER SPICER LOC RITE DYNEER ARB DYNEER ARB DYNEER DYNEER 526.17 Case.49 525.10 DN P/L DANA 60 30 SPLINE I PIECE CASE DANA 60 30 SPLINE 4.49 519.53 743.7. Empty 4.53 486.46 743.12 344 345.10 NUMERICALLY LOWER AIR LOCKER DANA 60 32 SPLINE FITS TRAC-LOC DIFFERENTIAL DANA 60 32 SPLINE FITS OPEN DIFFERENTIAL DANA 60 32 SPLINE TRAC LOCK 4.54 743.46 187.10 NUMERICALLY LOWER AIR LOCKER DANA 60 35 SPLINE TRACK LOC 4.12 262.56 NUMERICALLY HIGHER NON-ABS DANA 60 35 SPLINE POWER LOC 4.45 743.33 .61 $86.56-UP DANA 60 30 SPLINE 4.13 Case.56 .17 Pinion Seal.46 686. Com .Pirate4x4.82 $133.73 $76.38 $53.html 8/22/2007 .Extreme Four Wheel Drive Page 16 of 16 Cross Shaft Standard Spider Gear Kit 30 Spline Standard Spider Gear Kit 35 Spline Trac-Loc Clutch Pack Trac-Loc Differential Parts Kit 33810 706043-X 706702-X 707083-X 707084-X $23.39 $72.com/tech/billavista/60_front/index2.pirate4x4.52 [Page 1] [Page2] Get a GoStats hit counter http://www.