2003 Dana 60

[RT]

I've been thinking of going with a Dana 60 front. And all of a sudden I see a ad for a 2003 D60 .

I was going to hold out for a 78/79 , but the price sounds good on this one . $1000.00 for D60 front +10 1/4 rear, 4:10 gears.

Has anyone here used one of these years of d60's ,, is it worth the extra fabrication ?? or am I better off holding out to find a 78 / 79 axle ??


Thanks.

 

[scsm76]

The 2003 can be made to work, but the big downside to the 2003 D60 is it has 8 x 170mm lug pattern , ball joints, and unit bearings. Plus it offsets the diff more to the driver side than the 78-79. If you find a 1985.5 -91 D60 it will have a similar diff offset but have king pins, traditional bearings and the 8 x 6.5" lug pattern.
Here is a pretty thourough article explaing all the generations of D60 axles:
http://www.pirate4x4.com/tech/billavista/60_front/

 

[Broncobowsher]

The 2003 can be made to work, but the big downside to the 2003 D60 is it has 8 x 170mm lug pattern , ball joints, and unit bearings. Plus it offsets the diff more to the driver side than the 78-79. If you find a 1985.5 -91 D60 it will have a similar diff offset but have king pins, traditional bearings and the 8 x 6.5" lug pattern.
Here is a pretty thourough article explaing all the generations of D60 axles:
http://www.pirate4x4.com/tech/billavista/60_front/

What he said. I can't find anymore to add.

 

[welndmn]

They are harder to fit in an EB then the 78/79's but 1k for the set is a good deal.
The bolt patteren does not matter much because you have the rear end as well. I also like unit bearings. Ball joints suck IMO, but many get by just fine with them.

 

[KyleQ]

The 2003 can be made to work, but the big downside to the 2003 D60 is it has 8 x 170mm lug pattern , ball joints, and unit bearings. Plus it offsets the diff more to the driver side than the 78-79. If you find a 1985.5 -91 D60 it will have a similar diff offset but have king pins, traditional bearings and the 8 x 6.5" lug pattern.
Here is a pretty thourough article explaing all the generations of D60 axles:
http://www.pirate4x4.com/tech/billavista/60_front/

Incorrect - 78-79 has it's own pumpkin spacing. 80 and up has it's own spacing that isn't even close tot he 78-79 spacing. 78-79 D60's are getting to be worth their weight in gold and are getting hard to find.

Here is some pictures for ya - they are under my Dad's 78, but you get the idea.

86 Dana 60

78 Dana 44


As you can tell the radius arm wedges are hitting the pumpkin and the c wedge on the 86' D60 and on the 78 D44 there is plenty of room. On the 80+ D60's you need to grind down either the c wedge (if you go that route) or grind on the casting until the c wedge clears. Here is my 90' D60 I got - I got the Cage weld on kit because there is literly no room.


I'd say buy those axles for 1K - unit bearings, who cares - the EB is light and shouldn't be hard on them. Metric bolt pattern? Little tougher to find wheels, but you got a pair of axles for 1K - you have some breathing room there. Balljoints are ok - remember what that axle came out of and what that vehicle was rated for...

 

[RajinCajun]

I have an 03' D60 and 10.25 on my slab right now going under a buddies Heep.. Main problem would be the lack of room on the driver side by the pumpkin.. we are doing a 3 link with a track bar and it will still be a pain, but I don't think there is room to do a radius arm set up... Oh, we are also doing King coilovers.. Here is a pic or two.. Haven't put any of the front yet, I will try to get a few in the next day or so..
http://www.texasoffroad.net/galleries/ohv/album436
Sorry to put pics of a Heep here, but I figured it was warrented considering the subject and the exact axles you are looking at....

I used an 05' D60 and 10.5 under my Bronco.. it was originally radius armed with coils so it was a little easier to do...
http://www.bigcountryoff-road.com/Tech/BroncoAxleInstall.htm
I have better pics than are posted here of my axles.. I can e-mail a few if you are interested in some specifics..

 

[KyleQ]

I have an 03' D60 and 10.25 on my slab right now going under a buddies Heep.. Main problem would be the lack of room on the driver side by the pumpkin.. we are doing a 3 link with a track bar and it will still be a pain, but I don't think there is room to do a radius arm set up... ..

Take a look at the picture I posted above - the spacing is the same on your D60 as the one in the picture (or very damn close) and the radius arm setup fits.. The kingpin comes close to the coil cups - but it doesn't interfere.




Here is another shot...

 

[scsm76]

Incorrect - 78-79 has it's own pumpkin spacing. 80 and up has it's own spacing that isn't even close tot he 78-79 spacing. 78-79 D60's are getting to be worth their weight in gold and are getting hard to find.

Here is some pictures for ya - they are under my Dad's 78, but you get the idea.

86 Dana 60
View attachment 110662
78 Dana 44
View attachment 110663

As you can tell the radius arm wedges are hitting the pumpkin and the c wedge on the 86' D60 and on the 78 D44 there is plenty of room. On the 80+ D60's you need to grind down either the c wedge (if you go that route) or grind on the casting until the c wedge clears. Here is my 90' D60 I got - I got the Cage weld on kit because there is literly no room.
View attachment 110665

I'd say buy those axles for 1K - unit bearings, who cares - the EB is light and shouldn't be hard on them. Metric bolt pattern? Little tougher to find wheels, but you got a pair of axles for 1K - you have some breathing room there. Balljoints are ok - remember what that axle came out of and what that vehicle was rated for...

When I said similar diff offset. I was comparing it to the 2003 D60 not the 78-79. I guess I didn't make that very clear.;D
I've actually been searching for decent price on a 86-91 D60 I want to narrow a D60 to about 63-64" and a 78-79 would put the pinion too close to my engine unless both sides were narrowed. The later years should fit just right with just the long side narrowed.

 

[RajinCajun]

Take a look at the picture I posted above - the spacing is the same on your D60 as the one in the picture (or very damn close) and the radius arm setup fits.. The kingpin comes close to the coil cups - but it doesn't interfere.

View attachment 110893


Here is another shot...

The only front pic I have up is my 05' D60.. I don't actually have a pic of the 03' yet.. sorry.. the area available is only about 1.5" before the cast section starts for the spring perch..

 

[broncodude_73]

If you have a 10.25 rear then the bolt patterns won't match up. The 10.25 had a 8 on 6.5'' lug pattern. You would need a 1999 and up 10.50 to match the front 03 D60 lug pattern of 8 on 170mm. The 10.50 also had disk brakes.

 

[RajinCajun]

If you have a 10.25 rear then the bolt patterns won't match up. The 10.25 had a 8 on 6.5'' lug pattern. You would need a 1999 and up 10.50 to match the front 03 D60 lug pattern of 8 on 170mm. The 10.50 also had disk brakes.

You are correct I didn't realize the 10.50 was the replacement in 99'+.. We have a 10.50 the bolt pattern in the metric like my 05'.. Thanks for pointing that out..
http://www.fourwheeler.com/techarticles/drivetrain/129_0506_ford_1025_1050_inch_axle_tips/index.html

 

[RT]

Man,,, the FW D44 swap is starting to look good..

Seriously ,,,theres a lot of work you guys have done to get those D60's in there.

I think I'll keep the 03 in mind , but start looking for that 78/79 unit. Seems like a little more straight forward project.

Unless of course my lucky lotto ticket comes through,,,
Then it's Dynatracs for everybody !!!;D


Thanks for all the info guys ,, I'll have to get to work on this soon ...The Moab Safari is only 8 months away

 

[scsm76]

I don't think the strength of unit bearings is the downside, its more the cost of replacements and they need to be bored out to fit 35 spline stub shafts. They do make changing axles faster and cleaner.

 

[welndmn]

The only front pic I have up is my 05' D60.. I don't actually have a pic of the 03' yet.. sorry.. the area available is only about 1.5" before the cast section starts for the spring perch..

I just swapped one of those 06 Dana 60's into a dodge. For the deal it sure seemed sweet. 35 splines, pretty much new. But man what a PITA. We had to make new radius arms to match the stock for ones. A design I am not that much of a fan of.

 

[malcolmzilla]

My buddy just installed this hub conversion kit on his 04 1 ton dodge with an adjustable Kelderman airbag and link kit and 37's... I didn't ask if he did the 30 or 35 spline...

http://www.emsoffroad.com/products/hubconvert.htm

 

[RajinCajun]

Seriously ,,,theres a lot of work you guys have done to get those D60's in there.

Truer words have never been spoken