Dana 60

The Dana/Spicer Model 60 is an automotive axle manufactured by Dana Corp. and used in OEM "heavy duty" pickup applications by Chevrolet, Dodge, Chrysler, Jeep and Ford. There are rear axle and four wheel drive front steering versions of the Dana 60. It can be readily identified by its straight axle tubes, 10 bolt asymmetrical cover, and a "60" cast in to the housing. Gross axle weight ratings are often lowered by the vehicle manufacturer for safety and tire reasons.

Dana 60 Full Float(30 Spline, 4.10:1 gears, Limited Slip). From a 1999 4x4 Dodge 2500HD

General specifications

Every Dana 60 that was originally manufactured by Dana Corp (i.e. not aftermarket) is stamped with a build date and bill of materials on the back of the passenger-side axle tube. Owners can decode the bill of materials code here.

• Ring gear measures 9-3/4".
• 3.125" diameter axle tube.
• Weighs in near 500 lbs. More or less depending on width and brake configurations.
• OEM Inner axle shaft spline counts are 16, 23, 30, 32, 33 and 35.
• 40 Spline inner axle shafts and carriers are made for after market, high performance Dana 60 axles.
• Pinion shaft diameter: 1.625"
• Pinion shaft splines: 10 and 29
• Gear ratios: 3.31:1 - 7.17:1
• Carrier break: 3.31:1 - 4.10:1 and 4.56:1 - 7.17:1
• Axle Shaft diameter
  • 1.41” Front (32 Spline)
  • 1.46” Rear (32 Spline)
• Axle spline diameter
  • 1.50” Front (35 Spline)
  • 1.50” Rear (35 Spline)
• 1480 Universal Joint (Front axle)
• Brakes measure 13.66" for 2011 F-250 & F-350 trucks.
• Brakes measure 14.53" for 2011 F-450 trucks (13,050 GVW).

Dana 60 front steer axle

History

Ford was the first company to use Dana 60 front axles in 1955.^{[citation needed]} In the mid-1970s the Big Three (automobile manufacturers) all started using this axle. GM began phasing it out in 1988 in favor of Independent suspension, while still offering it in some higher GVWR trucks (V-30) until 1991. Dodge used a Dana 60 up to 2002. 3rd Generation Dodge Rams dropped the Dana 60 in favor of a lighter, reverse cut AAM axle. Ford still uses the Dana 60 front axle. Manufactured in both Kingpin and Ball joint variations, "standard" and "reverse cut" rotation variations and open and limited slip variations. The housing material is Gray iron in early axles and Ductile iron in later axles. GM and Ford Dana 60 axles utilize locking hubs. Dodge Dana 60 axles utilized locking hubs until 1994 when a Center Axle Disconnect (CAD) system was adopted. However model year 2002 Rams phased out the CAD system leaving some 2002 Dana 60 axles permanently locked in.

Big Three variations

• GM / Chevy versions are passenger side differential drop, standard rotation gears, kingpin knuckles and 35 Spline axle shafts.

• Dodge versions were passenger side differential drop, standard rotation gears, kingpin knuckles and 35 spline axle shafts in early models. The 2nd Generation axles were drivers side with ball joints. 30 Spline axle shafts were used instead of 35 splines, except 2000, 2001 and 2002 models which were equipped with 32 spline axle shafts.

• Ford versions are drivers side differential drop, reverse-cut gears, and kingpin knuckles up to 1991. The later axles have ball joints. Ford Dana 60 axles mostly feature 35 spline axle shafts.

Dana 60 aftermarket

The Dana 60 front axle has a great deal of aftermarket/third-party support, including many upgrades. Stronger axle shafts, Universal Joints and ball joints are widely available. As well as a large selection of traction control devices such as Locking differentials and Limited slip differentials. Axle shafts, Universal joints and carriers made from chromoly steel are even available. High capacity differential covers are available that increase the amount of oil the differential holds. These covers also feature Heat sinks that help keep the axle cool.

Dana Super 60

Dana Super 60 from a 2008 Ford F-450

The Dana Super 60 is an upgraded version of the Dana 60 front axle.

Differences in the Dana Super 60 versus the regular Dana 60:

• Larger and thicker diameter steel tubes (3.75 inches diameter and 1/2 in thick)

• Larger ring and pinion which increase the contact area and overall strength.

• Larger Universal Joints which increase strength and steering angle.

• Super 60s use 1550 Universal Joints.

• Net formed spider gears for increased strength.

• All made with 35 Spline axle shafts.

This axle was used only as a medium duty unit until the Third Generation F-450 Pick up began production. The Third Generation F-450 pick up is a light duty truck. This axle is still used in the medium duty F-450 and F-550 4x4 trucks as well.

Dana 60 rear axle

The Dana 60 rear axle was first introduced in 1955 as a full floating axle in Ford F-250's and is still used today.

• Manufactured in both full float and semi float variations. The semi float axles have GAWR up to 5,500 lbs and the full float axles were rated up to 6,500 lbs.

• Full floating, 30 Spline, variants are common. 35 Spline semi-floating and full floating axles exist, but are less common.

Dana 60 rear steer axle

Quadrasteer

Quadrasteer was a option in 2002-2005 GM full size, single rear wheel trucks. Constant-velocity joints were used instead of Universal joints.

Dana 61

A variation of the Dana 60 known as a Dana 61 was made to accommodate gear ratios that allowed for better fuel mileage. This was done as a direct result of the 1973 oil crisis. A 3.07:1 gear ratio was common for these axles and unachievable in a regular Dana 60. To allow for the different gearing, the Dana 61 had a greater pinion offset. This offset meant that a different carrier and a different ring and pinion had to be used. The Dana 61 was made in semi-float and full-float axles for select 4x2 Ford 3/4 Ton and 1 Ton Pickups and Vans from 1974 - 1987. A Dana 61 front axle was selectively used in Dodge 4x4 3/4 Ton and 1 Ton pickups from 1987 - 1993. Although 3.00:1 and 3.07:1 gear sets are possible from a Dana 61, lower gear sets (4.56:1 on down) are not.

Dana 53

The Dana 53 first appeared in the late 1940s and is much like a Dana 60. Although all Dana 53's are semi-floating, rear axles. The Dana 53 was phased out in the 1960s by the Dana 60.

Common Applications^[1]

Front Axle

International Harvester

• 1975 1300 Camper Special

Chevrolet

• 1977-1991 1Ton (K30/V30)
• 1984-1988 Commercial Utility Cargo Vehicle

Dodge

• 1975-2002 3/4 Ton (D-600/W-250/2500)
• 1981-2002 1 Ton (D-700/W-350/3500)

Ford

• 1974-1979 F-250
• 1999-2011 F-250 (Optional)
• 1974-2011 F-350
• 2000-2004 F-450/F-550

'Dana Super 60'

• • 2005-2010 F-450/F-550 (Dana Super 60)
  • 2011 F-550 and class 4 F-450.

Rear Axle

Studebaker

• 1956-1964 E12 3/4t and E14 1t

Dodge

• 1966-1970 Coronet & R/T
• 1966-1972 Charger & R/T
• 1968-1972 Super Bee
• 1970-1971 Challenger
• 1963-1993 Dodge Ram 2500 and 3500
• 1994-2002 Dodge Ram 2500 (V8 Only)
• 2004-2006 Dodge Ram SRT-10

Plymouth

• 1966 Belvedere
• 1966 Satellite
• 1968-1972 Road Runner
• 1967-1971 GTX
• 1970-1971 'Cuda

Ford

• 1955-1985 Ford 3/4 Ton Trucks
• 1955-1976 Ford 1 Ton Trucks
• 1980-1998 Ford E200/E250/E350 vans

Chevrolet

• 1964-1977 Chevrolet and GMC 3/4-ton pickups
• 1975-1987 Chevrolet and GMC 1-ton pickups and Suburbans
• 1979-1991 Chevrolet and GMC 1-ton vans
• 2001-2010 Chevrolet and GMC 1-ton vans

Jeep

• 1968-1973 Jeep J3800/J4800 Camper Truck (full float 30 spline)
• 1968-1970 Jeep J-2600/J2700/J3600/J3700 (semi float 35 spline)
• 1971-1973 Jeep J4600/J4700 (semi float 35 spline)
• 1974-1988 Jeep J20 (full float 30 spline)

References

1. ^ Incomplete list. Common applications only.

External links

• http://www.pirate4x4.com/tech/billavista/60_front/index.html
• http://www.akfabshop.com/alaskaoffroad/axle_tech.htm
• http://www.autohobbydigest.com/dana.html
• http://www.hemmings.com/mus/stories/2006/04/01/hmn_feature27.html
• http://www.therangerstation.com/tech_library/Dana_BOM_numbers.html

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