Dana 60 axle swap - Ford Truck Enthusiasts Forums
- Big Bronco - Dana 60 axle swap - The answer to this may be obvious but I just put a in my Bronco and I want to put dana 60's. Bronco base buggy. Four link front and rear. Front Dana 35 spline chromoly axels arb locker. Sterling rear ford to a zf5 speed tranny to a klune. Welcome to CRAWLER SWAP MEET now with no drama. Posting rule is simple 02 ford Dana 60 with and a 14 bolt with and a posi. I will load some.
Recently I designed my own arms, and came to the same conclusions. Side loads were going to be a problem and the trac bar was going to require some real beef to keep the axle from ripping out during vehicle recovery.
Now my applicaions may be very different than most, and the mud I get into is heavy and thick. This style of mud has ripped leaf spring hanger clean off of the frames of some vehicles, and I was concerned about this link style systems.
SImply put the lack of mounting points makes this style not suitable for my applications. Perhaps a dedicated trail rig, or something that may not see such extreme loads may benifit from some aftermarket long arms, but keep some of this in mind when you consider your build.
This was a direct weld on, with minimal modification. Wedges were available from James Duff for about 80 dollars US and only required a little grinding to accomodate the larger D60 axle.
You can use a later model Dana 60, but the driverside spring perch and differential is located quite further to the driver side, making the driver side short tube a little too short to attach any mount for a radius arm.
"ford dana 60" in Classifieds in Ontario
Some folks remove half of the perch, by cutting it away, but I have also seen some of these break in this area if the truck sees any kind of impacts, or higher speed hits. That tube just does not have the strength any longer so some provisions have to be made. You may consider steeping up to a non tapered shaft for ultimate strength. All of them will also have small 30 spline stub shafts, and these are a very weak area on these axles.
The Stage I kit is for those who already have a 4" or 6" suspension lift. Our 4 stage powder coat is optional but highly recommended. The Stage II kit consists of everything mentioned above as well as coil springs, two Bilstein Series shocks, shock adapter brackets for top eyelet style shocksextended brake lines and all grade 8 mounting hardware.
Our 4 stage powder coating is optional but highly recommended The Stage III kit will consist of everything mentioned in the Stage II kit as well as, Bilstein Series dual rate Coilover shocks, upper Coilover tower, coil springs, extended brake lines, Bilstein Series Hydraulic bump stops, Bump Stop Brackets, limit straps with hardare and all grade 8 mounting hardware.
Here is the nitty gritty on the kit. It is designed as a direct bolt on application for the Bronco and F No cutting, welding or measuring is required except for cutting off factory radius arm brackets from the truck frame and the Dana 60 axle.
It is designed to work with the mid 80's to mid-late 90's Ford Dana 60 axles, both the king pin and ball joint versions. The Dana 60's and the 98 and newer Dana 60's are not compatibale with this kit.
It is a complete bolt on kit with only minimal drilling required. The only holes that need to be drilled are three easily drilled holes in the side frame rail for the radius arm brackets, and one existing hole for the track bar bracket that simply needs to be drilled out larger.
There is no welding required. It is designed with all measuring built in to the hole locations for easy, measurement free installation Alignment is required. The kit will work with both versions of coil springs or Adjustability is fully built in with the ability to have the axle positioned anywhere from 1"-3" forward of stock. Caster adjustability is also built in.
It can be adjusted at the axle spring perch with caster adjusting shims, or at the radius arms with caster adjusting "picture frame" pieces.
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Most of the time adjustment will not be necessary. The radius arms are a boxed style arm built with all. They are pure beef and simply can not be broken! They have a tight inward bend to accommodate large tires and they have a high clearance profile to avoid rocks and debris.