info on a dana 60 97 f250 swap - Ford Powerstroke Diesel Forum
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post #1 of 5 Old 03-20-2014, 08:56 PM Thread Starter Rookie
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info on a dana 60 97 f250 swap

hi everyone. i am looking to do a dana 60 front axle swap on my 97 f250. ive been doing research for a little bit it seems that i want to find one on a 92 to 97 f350. all i am looking for are problems that people have ran into. ive heard about the driveshafts from f250s being too long. seems like alot of problems. what would be the best way to get that thing up in there. thanks.
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post #2 of 5 Old 03-21-2014, 10:56 AM
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The front drive shaft needs to have an inch removed from it when you do a d60 swap. The easiest way to get everything you need is to find a wrecked f350. I was able to buy my axle complete with suspension brakes everything for 500. Spent 500 on gears to make it match truck. Another 300 on brakes and seals couple hundred on spring bushings and a couple hundred on shocks just because my shocks were shot. I then paid 200 to have driveline shortened to fit and spicer u joints put in it. I also put spicer joints in axles.

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post #3 of 5 Old 03-24-2014, 05:42 PM
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There are some really good write ups available foe the d60 conversion. I used one from an org member named mjonesjr. Just use the search and you should see it. Very helpful.

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125,000 miles, Full Force Stage 1 Injectors, 4:10 rear, Dana 60 Swap, F350 Rear Lift Blocks, 325/60R18, 3" Down Pipe, 4" Exhaust, Tymar Intake, Aeoroforce Interceptor, DP Tuner (no start, stock, high idle, drive thru, 80 Eco, 60 Eco, 60 tow, 120 hp Race Tune), 7.3 Intercooler, 2.25 PMF RSK, V-Code Front Springs, B Code Rear Springs, Complete Alpine Audio System Upgrade, Tru-Cool Trans Cooler, Pro Comp 1069 18x9 Rims, John Woods Tow Master Transmission, Air Lift Air Bags
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post #4 of 5 Old 03-24-2014, 06:54 PM

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If yours is a 97 you do not need to shorten the drive shaft, it's a direct bolt in process and once you remove the TTB and slid the d60 under your going to think it was the simplest thing ever (it's easier then installing an Intercooler) you want an f350 front end hub to hub preferably, from 1986-1997, the 86-94 have slide pin calipers, the 95-97 have bolt on ones, but if the later you can use your current calipers, everything literally just goes in as it came out, have fun

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post #5 of 5 Old 03-25-2014, 07:25 AM Rookie
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definitely give the d60s you look to buy a real good go over. I did not check anything but the gears and diff when I did my junkyard/craigslist shopping. I did the gears, and inner seal, bearings etc. and ball joints before I put it in. Later realized I installed an axle that needed one new spindle new spindle bearings, wheel bearings, short side axle (inner and outer) and ujoints!
In the end my dana 60 swap and rsk was one of the most expensive things I have done to this truck.
So don't be a dummy like me and try to source a axle that is in good shape.

Also, I cannot say enough about the SD springs and RSK. Best thing in the world! Dollar for dollar the best money I have spent on this pickup by far. Rides like an entirely different truck especially on bumpy terrain.
Also I got better turning radius with d60. Also no did not have to shorten my drive line. truck has a little lift to it from rsk so I don't know if that had any effect its, it only a couple inches so I doubt it.
Its a pretty strait forward swap and it will just feel awesome to see that junk twin beam in the scrap bin when your done!

Good luck

95 F250 xl - auto trans - Dana 60 front under sd springs and PMF rsk - rs9000 shocks - 285/75r16 GY Duratracs on eagle alloys -
Inside: 4 pod A-pillar with isspro boost, egt, and trans temp. , bt OBD reader and torque app. Also added tilt and cruise.
Under hood: 7.3psd, rw 160/30 injectors, PHP Hydra with php & gearhead tunes, afe intake/filter, 3" down pipe.
Coming soon: efuel, turbo, c.a. cooler, and bigger hpop.
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