The Dana 60 front axle is a heavy-duty 4wd front steering axle manufactured by Dana Spicer corporation. It was most commonly used in many one ton and some 3/4 ton pickup trucks.
Over the years there have been many different variations, from early Ford closed knuckle low pinion types, to the common GM kingpin low pinion, to the 94+ Dodge Dana 60 with a vacuum operated central axle disconnect, balljoints, and 32 spline inner shafts.
The most desirable axles for heavy duty 4x4 use in stock form have open kingpin knuckles, 35 spline inner axles, 30 spline outer axles (stub shafts), and disc brakes. Later model Ford high pinion (HP) Dana 60s with balljoints instead of kingpins are also desirable axles, though many prefer the kingpin knuckles over the balljoints.
The undesirable front Dana 60 axles will not be covered by this article, and include:
74-75.5 Ford low pinion drivers side closed knuckle drum brake with 30 spline inners, 19 spline outers, small ujoints and weak knuckles.
75.5-77 Ford low pinion drivers side open knuckle disc brake 30 spline inners, 19 spline outers, outer knuckle spindle pilot hole is smaller than 78+ axle and is therefore notched to allow 1480 series U-joint tp pass through.
94+ Dodge drivers side low pinion CAD unit bearing hub 32 spline 1.31†coil sprung Dana 60s
Any other closed knuckle Dana 60, like those from a Jeep M715 that had coarse spline axles.
Common applications for the desirable axles include:
GM
1977-87 K30 1 ton 4wd
1984-88 CUCV
1988-91.5 V30
All GM / Chevy versions were passenger side differential, regular rotation (low pinion) gears, disc brakes, 35 spline inners, 30 spline outers, internal style hubs, and kingpin knuckles.
Dodge
1975-89 D-600
1992-93 D-600
1981-89 D-700
1992-93 D-700
All these Dodge versions were passenger side differential, regular rotation (low pinion) gears, disc brakes, 35 spline inners, 30 spline outers, and kingpin knuckles. 1979-89 versions had external style hubs, with the earlier versions with full-time NP203 Transfer cases having external drive flanges, and later models having external lockout hubs. The external lockout hub bolt pattern is 8 x 3.960". The 90-93 versions had internal style hubs just like the Chevy and lockout hubs. One caution with dodge applications, is you have to be careful to avoid the Dana 61 front axle. 1987-88 and 1991-93.5 Dodge D600 and D700 also came with Dana 61. More info on the Dana 61 later in the article.
Ford
1978-79 F-350 and some F-250 (Snofighter and High GVW packages)
1986-88 F-350 with dual rear wheels (DRW)
1988-91.5 F-350 with single rear wheels (SRW)
1992-95 F-350 (all) (balljoint)
1996.5-98 F-350 (all) (balljoint)
2000 F350/F450/F550 DRW (balljoint, metric 8x170mm wheel bolt pattern F350 / 8x220mm F450/F550, unit bearing hub)
2000.5 F350/F450/F550 DRW (balljoint, metric 8x170mm wheel bolt pattern F350 / 8x220mm F450/F550, unit bearing hub)
2001 F350 DRW (balljoint, metric 8x170mm wheel bolt pattern, unit bearing hub)
2001-02 F450/F550 DRW (balljoint, metric 8x220mm wheel bolt pattern, unit bearing hub)
2002 F250/F350 SRW (balljoint, metric 8x170mm wheel bolt pattern, unit bearing hub)
2002 F450/F550 DRW (balljoint, metric 8x220mm wheel bolt pattern, unit bearing hub)
All these Ford versions were drivers side differential, reverse-cut (high pinion) gears, and kingpin knuckles to 1991.5 and balljoints thereafter. Most Ford D60s are internal style hubs, but external type lockout versions do exist. 2000 and later Ford D60s have balljoints, a metric wheel lug pattern of 8x170mm up to F350 and 8x220mm for F450/F550, different brakes and spindles, sealed "unit-bearing hubs", hub-centric wheels, different length axleshafts from the earlier D60s, and larger Superduty specific tie rod ends. From 2000 on, the Ford D60 front axle is also known as the Model 60F2000+ or the 248M. 248 just happens to be the equivalent in millimeters of 9.75" - the diameter of the D60s ring gear.
IHC
1975 1300 camper Special
35 spline inner, 30 spline outer, external lockouts
