Dana 60 Swap Complete!!! - Ford Powerstroke Diesel Forum
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post #1 of 23 Old 03-16-2008, 07:28 PM Thread Starter
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Dana 60 Swap Complete!!!

Finally, I have swapped out the TTB Dana 50 axle, for a straight Dana 60 unit!!


The truck's mileage was getting up there, and it was time to replace a few worn parts. So I figured this would a good time as any, to do the swap. So awihle ago, I searched for a Dana 60 axle. Prices were high for the axle alone, so I just bought a parts donor truck, removed the axle, and parted the rest of the truck out.

And (slowly), I have been rebuilding that axle. My new replacement is a 1997, which I wanted, so that my recently replced rotors and such, would transfer over. And now this axle has everything new, except the housing and differential!!

Not too bad of a swap. Just was a bit difficult trying to do everything by myself, but somehow I managed.

I still have a few more things to do, such as swap out the springs, add the sway bars, etc....... But the big and heavy work is done!!
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2008 Dodge 2500 Mega Ram, 6.7L, 4x4, 3.73s

SOLD...
1997 F-250 HD, PSD, XLT, Off-Road Pkg., 3.55's, E4OD, 4wd, Dana 60 front axle, 3" Sky RSK, 150,000 miles, Tunes by XM, triple Auto Meter Guages, Tymar Intake, Tymar DP, Straight piped, Killed the kitty, 5" Miters, Programs by DP Tuning, Lund visor, Diamond plate bed rails, Delta toolbox, Rollin' on 315/70/17's on some Raceline's.
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post #2 of 23 Old 03-16-2008, 07:29 PM
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awesome job man, i like the color of your truck..

im still alive and kickin...find me on FB..."StrokerX1"
SOLD my truck, another Diesel within 2011

NOTE: if your on OK and need some PSD work done, i know a dealer tech who does the work....PM me!
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post #3 of 23 Old 03-17-2008, 10:12 AM Thread Starter
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Thanks man! Just glad to finally get this job done. It has been sitting in my garage..................of for a few months!

2008 Dodge 2500 Mega Ram, 6.7L, 4x4, 3.73s

SOLD...
1997 F-250 HD, PSD, XLT, Off-Road Pkg., 3.55's, E4OD, 4wd, Dana 60 front axle, 3" Sky RSK, 150,000 miles, Tunes by XM, triple Auto Meter Guages, Tymar Intake, Tymar DP, Straight piped, Killed the kitty, 5" Miters, Programs by DP Tuning, Lund visor, Diamond plate bed rails, Delta toolbox, Rollin' on 315/70/17's on some Raceline's.
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post #4 of 23 Old 03-17-2008, 10:18 AM
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Looks good! Im looking for a 60 front right now and everything is 1000 bucks on up

2002 F-250 4x4 EC, SRW, SB
Auto 93,000 miles
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ATS Compressor and 1.0 Exhaust housing high flow back plate
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post #5 of 23 Old 03-17-2008, 10:27 AM Thread Starter
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Quote:
Originally Posted by vitalidle View Post
Looks good! Im looking for a 60 front right now and everything is 1000 bucks on up

I know what you mean..........that is why I bought an entire truck. Everyone was 'too proud' of the axles they had. So I bought a truck, took off what I needed, and parted out the rest. Plus it was good because I took all of the sway bar brackets (front and rear), rear leaf spring overloads, etc..etc...

Good Luck!

2008 Dodge 2500 Mega Ram, 6.7L, 4x4, 3.73s

SOLD...
1997 F-250 HD, PSD, XLT, Off-Road Pkg., 3.55's, E4OD, 4wd, Dana 60 front axle, 3" Sky RSK, 150,000 miles, Tunes by XM, triple Auto Meter Guages, Tymar Intake, Tymar DP, Straight piped, Killed the kitty, 5" Miters, Programs by DP Tuning, Lund visor, Diamond plate bed rails, Delta toolbox, Rollin' on 315/70/17's on some Raceline's.
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post #6 of 23 Old 03-17-2008, 10:30 AM
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Thanks! Looks like Im just going to have to pony up I guess

2002 F-250 4x4 EC, SRW, SB
Auto 93,000 miles
DP Tuner F5
ATS Compressor and 1.0 Exhaust housing high flow back plate
Turbo Back 4" Silverline Exhaust Mbrp Muffler Delete
Isspro Trans,Pyro,Boost Triple Pod
Fumoto Oil Drain Valve
AIH Delete With Boost Fitting

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post #7 of 23 Old 03-30-2008, 11:45 AM
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Hey man your truck looks great. I did the same thing but ran into few problems. I want to run a few things by you and please let me know what you think. I did the leaf spring center pins have any play on your dana 60 or was that a real tight fit? Mine had a little free play and some of my friends say I have a slight crab going down the road. The other is are your front tires siting out wider then your rear tires? I had a problem with my track bar. it seams to have move the whole axle to the right like 1 inch. I might take it off or find an ajustable bar. Please help if possible. I am happy that I did this but I am upset that I am dealing with these little problems. I am not sure if this has anything to do with it but I have an add a leaf in the front for a 2 inch lift. My only thoughts are that I am going to need 2 bigger center pins for the springs. and take off the track bar. I also think that the track bar has pulled the right side back an half inch to cause the crab like movement. Thanks
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post #8 of 23 Old 04-06-2008, 10:20 AM
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You must use a track bar, either get a adjustable one or make your own. Any lift will require a different length track bar to recenter the axel! Reinstall the bar after the truck is on the ground and drive it back 20' or so then back forward..then install the bar.

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post #9 of 23 Old 04-06-2008, 10:36 AM
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looks sweet

IF CAPS ARE ON IM AT WORK I CANT TAKE THEM OFF
willypscustom cold air intake
4" exhaust straight piped
banks 6 gun
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agr hydro. assist steering
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and some other small mods
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post #10 of 23 Old 04-08-2008, 09:31 AM Thread Starter
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Thanks for the comments!


I finally got the 3" RSK installed, and some other associated stuff, completed and the front end aligned. So I am finally driving it around town. I will get some updated pics soon - probably from Smokin' N the Smokies event this weekend!!!

Nick,
When I originally installed the front axle, I just kept my OBS F250 springs in there. The pins 'seemed' like they were too big for the relief in the axle. But I didn't measure the pin, or the hole in the axle housing. And I didn't drive it until I did the rest of the wrk. But when I put in the OBS F350 springs, they dropped right into the axle housing. Not sure about the crab walk, as I can't check out my truck from behind whole I drive!! But I am still running my original track bar, and didn't have too much trouble with it. And yes, my tires do stick out of the fenders a bit. Oh well, I guess fender flares will be in the future!

2008 Dodge 2500 Mega Ram, 6.7L, 4x4, 3.73s

SOLD...
1997 F-250 HD, PSD, XLT, Off-Road Pkg., 3.55's, E4OD, 4wd, Dana 60 front axle, 3" Sky RSK, 150,000 miles, Tunes by XM, triple Auto Meter Guages, Tymar Intake, Tymar DP, Straight piped, Killed the kitty, 5" Miters, Programs by DP Tuning, Lund visor, Diamond plate bed rails, Delta toolbox, Rollin' on 315/70/17's on some Raceline's.
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