I did the Dana 60 swap two years ago. After having the IFS crack on the drivers side twice, that was all I needed
. It was a fairly simple swap. I had put new aftermarket springs on when I fixed the left axle housing the first time. I went down to my local spring shop in town and they set me up with what are comparable to "X" springs you will see talked about on here, well a little bit nicer than "X" springs. There are three things that are different or that you need to change. I was lucky enough to get my 60 with all the tie rods, if you don't, you will need them I think
. The ones I got bolted right in and work with no problems. When you find your donor vehicle, make sure to get the left side spring mounts, Ford doesn't stock these anymore. I was lucky enough to find them at a place by me that buys up all left over overstock items that the manufacturers discontinue. You will have to shorten your front driveshaft, I shorthened mine 1.5", and seems to be perfect.
. The last thing is the track-bar, I think that is what it is called...it needs to be longer. I went to the local race shop and bought two himey ends and a 1"x17" bar, that gave me enough adjustment to play with. I found that I had to grind the mounting bracket on the truck side back about a inch, so that it wouldn't hit the differential on severe bumps. Other than that, it was a fairly easy swap, and have no regrets.
I have played around with the adjustments on the track-bar a few times and have dialed it in pretty sweet. Does the truck ride different than before, yes, but it still is a damn good riding 250 on a 350 suspension.