Join Date: Nov 2007
Location: Blairsville, PA
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Terry pretty much covered this all for you.
It all depends on what you find, where you find it, and its condition.
Many men have searched years and not found an axle, and some people find them daily for dirt cheap.
I had an axle, picked it up for 500 bucks, and then I had about 500-600 in rebuilding it. Either way, the magic number seems to be right around 1100 dollars for a Dana 60 front axle. Id NEVER pay 1000 bucks for one that was just pulled from a truck, and not gone through. At one time, I did find a Dana 60 in a junkyard for 200 bucks. I picked it up, we put a new drag link on it, and swapped it into my buddies F250. He had to re-gear it, but othe than that, I think the total for that thing was under 500 bucks in parts, including the axle.
Any axle from 86-97 will work, but the 95-97 brakes are different from the 94 and older brakes. So youll have to do some brake line modifications to use the older calipers. The 91 and older axles are also King Pin, instead of Ball Joint. Kingpins are generally stronger, and will last longer, but are also considered "old" technology, and are harder to align than a balljoint axle. But once done, it will never "fall" from alignment until the king pins start wearing.
If you want to go a little more indepth, you can swap to the 99-04 axles, and youll have to do a little more modifications, IE: Brake lines, track bar, get the rear axle, and buy new wheels
OR you can go REALLY indepth, and do the 05+ axle swap, and youll have to get a lot more parts, remove a lot more parts, do some welding, a ton of drilling, including what youd need to do for the 99-04 axles. but is completely worth it.
Its all a matter of budget, and what you really are capable of/what you want.
Too many projects. Too little time...
Last edited by weareweird69; 02-04-2012 at 10:23 AM.