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Old 05-20-2013, 12:18 PM
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D60: rebuild or scrap it?

My 99 E350 'stroke van has a sick D60. The pinion bearings are noisy and the posi is making some clunking. I'm thinking about some go-fast goodies (intercooler, chip, intake, exhaust) and I'm a bit concerned about how strong that D60 really is.

And then I did a search and it looks like a bunch of you guys are swapping TO the D60.

Should I just rebuild the D60, or should I look for different SRW axle? Are there any obvious, easy axles that fit as an upgrade to the 60?
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Old 05-20-2013, 11:04 PM
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The D60 is a really good front axle. There isn't anything that will be a direct easy upgrade to the D60 and it's already a custom install in a van. If you are doing something extreme then look into a 2.5 or 5 ton Rockwell for both the front and rear.
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Old 05-21-2013, 04:13 AM
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I would rebuild the one you have. The d60 is about the best front axle you can use. While not bullet proof, it is very stout. Im not sure a truck d60 would be a direct bolt in unit and it would be used. Rebuilding yours will ensure that the axle lasts
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Old 05-21-2013, 04:07 PM
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Oh goodness.... This is a rear axle, guys.

D60 would be GREAT in the front, this is the factory rear. 9.75" FF
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Old 05-21-2013, 10:49 PM
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I thought the vans used a D70 in the rear. A D60 is fine in the rear if you arn't towing really heavy. The trucks use a Sterling 10.25 or 10.5 depending on year. The 10.25 uses the same 8x6.5 pattern as your van but has drum brakes. I don't think either would be a direct bolt up, might not even be the correct width. I would just rebuild whatever axle you have and use good parts like Timken for the bearings.
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Old 05-22-2013, 08:30 PM
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A few of the vans got the D70, but with the same 9.75" carrier as the D60. If I had the D70, I could swap for the larger carrier and add a bit of torque capacity, but I don't. I do occasionally tow 10k or more, but the full-floater D60 like I have should be fine with the weight.

I'm more concerned with being bulletproof for towing AND mild mods. I'm thinking with intake, chip, exhaust, and intercooler I could be giving that rear axle 750 ft-lbs of torque in a heavy van while not towing and 600 ft-lbs while dragging 10k.

I'm looking for an axle that will take that kind of abuse on a daily basis and not whine about it... literally.
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Old 05-26-2013, 07:12 PM
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I'm in the same position your in. My Full Floater doesn't sound sick.yet. But when I drained the oil, a chunk of what others have told me is bearing shim came out.

The PO built my van to tow and he used it for that for at least 100k.. So I cant decide if I should simply rebuild my D60FF or look for a D70 or D80.

D70U has a D60 bearing kit with a different ID on the pinion head bearing bore, other than that, they are identical. When you get into the 70B, you get the larger pinion head bearing. And then when you get a 70HD, you get the larger pinion head bearing and the Dana 80 sized carrier bearings.

So for D60 owners, anything less than a D70HD wouldn't be worth the hassle. Another option would be a D80.. But did ford put D70HD's or D80's in SRW full body E350's? I think they were only in cutaway/box DRW. I'm not sure what it takes to convert from DRW to SRW. Probably nothing, but the dually width which I think is 72" wms-wms is to wide compared to the 66.4" of all the SRW full bodied E350's.
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Old 05-26-2013, 07:21 PM
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Quote:
Originally Posted by rebar View Post
D70U has a D60 bearing kit with a different ID on the pinion head bearing bore, other than that, they are identical. When you get into the 70B, you get the larger pinion head bearing. And then when you get a 70HD, you get the larger pinion head bearing and the Dana 80 sized carrier bearings.

So for D60 owners, anything less than a D70HD wouldn't be worth the hassle. Another option would be a D80.. But did ford put D70HD's or D80's in SRW full body E350's? I think they were only in cutaway/box DRW. I'm not sure what it takes to convert from DRW to SRW. Probably nothing, but the dually width which I think is 72" wms-wms is to wide compared to the 66.4" of all the SRW full bodied E350's.
From what I understand, the only D70 SRW (at least in Ford Vans) was the 70U and like you said its basically the same critter as the D60.

I did a lot of measuring on AAM 10.5 and AAM 11.5 axles since I can find them in SRW configurations, but the main problem I have is the lack of Ford-style speedo sensor bungs in the housing. I have a 10.5FF sitting here, and I could do some mild mods to make it fit, but then how do I get a speedo signal?

I was hoping (in vain I think) to find something stronger (and by that I mean overkill) that will more or less swap in with creative parts choices instead of customizing a housing for a sensor, and machining a reluctor for the pinion...
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Old 05-26-2013, 07:51 PM
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Quote:
Originally Posted by curtis73 View Post
I was hoping (in vain I think) to find something stronger (and by that I mean overkill) that will more or less swap in with creative parts choices instead of customizing a housing for a sensor, and machining a reluctor for the pinion...
I like your philosophy. Overkill. Those AAM 10.5 and AAM 11.5 axles you "found" would be overkill and sorry I cant help with the speedo. I wish I had the capability to swap one of those in for piece of mind.

I'm not as experienced as you and will have settle for a rebuild unless a D80 SRW is available. If not, any suggestions on which brand of replacement seals/bearings I should choose? I want a selectable locker on new 35 spline axles. Does anyone build a rear like that? I need one asap.
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Old 05-27-2013, 08:34 AM
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Quote:
Originally Posted by rebar View Post
will have settle for a rebuild unless a D80 SRW is available. If not, any suggestions on which brand of replacement seals/bearings I should choose? I want a selectable locker on new 35 spline axles. Does anyone build a rear like that? I need one asap.
As far as brand, I usually buy an entire kit from Timken. That often only includes stuff for the center section, not outer bearings and seals. But the same supplier can add those on and give you the same brand. Timken kits often come with any number of seal brands in them, but they're pretty picky about quality control.

Selectable locker will have to be something aftermarket - Detroit or ARB are good. Auburn makes an electronic locker but not sure if they make it for the larger axles.
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