Hi all. I have a '78 F-250 build in which I'm doing a Cummins swap. I've noticed a lot of guys changing out the Dana 44 front for the Dana 60 front, but I haven't done so. I've also already put a lot into refurbishing my 44.

What is the difference between the 44 and 60?

What is the reason for the swap and is it necessary? It it one of those "might as well while you're at it" kind of upgrades, or will the 44 actually have load capacity issues with the big heavy diesel?

Thanks

 

The 44 will work fine. People put a 60 in there because it can take more of a pounding from the extra torque the diesel produces. If you don't plan on 'wheelin' the crap out of it or jumping it, the 44 will probably hold up just fine.

 

I agree, the d44 is a strong axle!

 

Thanks fellas, you're saving me a bunch of money.

Maybe someday though

 

Agreed, I think the D44 is strong enough. I'm still running my D44 and have a '78/'79 D60 sitting in the garage. The longer it sits there the longer I'm debating not changing it out.

 

Here is some words of advice from a fellow FTE member (not me I am only the cut and paste guy).

D44 versus D60: But you will have a hard time finding a 60 with the 32.5" spring spacing, it'll have to be from a dentside. The '86+axles are spaced at 36", but are more common. Honestly the price you pay for one is way over rated. I happened to get one and put it in my truck, but it is just bragging rights to say "Yeah...I got a D60 front axle." They are over rated unless you continually are beating on it so hard you are tearing your D44 apart all the time.
The truths:
Yes it is heavier...doesn't do much but slow your truck down.
Yes it has a bigger ring gear...haven't broke yours, so why need to go bigger?
Yes it has bigger u-joint...good news is that likely won’t break on you.
The pitfall:
(The outer shafts are the same diameter as the outer shafts on a D44) POSSIBLY INCORRECT (just a different spline count). Instead of maybe breaking a u-joint you will likely break an outer shaft and good luck finding a cheap replacement.
The D44 held up for you for now, why change it? Also spare parts for the 44 are cheap. If you have 3:55 gears now and want to find 4.11s just find a D44 with 4.11s in already. I wouldn't pay more than $200 for a D44 front...they are very common. One questions for this would be what size tire are you running? For off road use the D44 is usually good 35" and under tires (yes there are many exceptions for this). If you rebuild the D44, do you plan on putting in after market (stronger) axle shafts and u-joints (or do you already have them). Load rating tests show that a fully upgraded D44 axle with good aftermarket shafts (there are LOTS to choose from and some are far better than others) is about equal to a stock D60 with 35 spline outer stubs. Ok now you just upgraded your axle shafts... what does your current ring and pinion look like? If you are eating up teeth or snapping pinion shafts there is really no fix for this but to go to a D60... well there is one possible option and that’s a Dana 50 which is a kit to drop in D50 gears into a D44, bigger ring gear but same pinion shaft diameter. If you are going to regear and going to keep the D44 this might be a good time to look at this option for increased strength. Last question is... with the plow on the front and any extra weight are you over the D44's load rating? If you are really working it hard do you know if your D44 is still strait and are you overloading the wheel bearings? Might be time to weigh the front half of your truck and see where you are at. An axle truss might help, but I'd say if you are past the 44's weight I'd move on to a 60.

 

The only input I have is related to above. Dana 44's have a gross axle weight rating of 3,500 lbs. the Dana 60 has a gross axle weight rating of 6,500 lbs. with the added weight of a cummins you may be pushing it upon weight transfer with hard braking. This is not to say that a Dana 44 won't last a long time as it is. However, you may go through ball joints faster because of the extra weight.

 

You guys have all been very helpful thank you. I think the answer is stick with the Dana 44, and consider a Dana 60 sometime in the future if I feel rich and bored. Thanks again.

 

I've been running a D44 under a cummins for...a year? Maybe longer...I cant remember when I started driving my swap.

Anyhow. I go through ball joints at an incredible rate, but I did when I was running a 400 as well. I made the mistake of buying cheap ones (but have a life time warranty) and I think that's my deal. I'll probably wear out the bores the joints press into before anything serious happens to the axle.

 

Another option to consider would be a solid Dana 50 from 99 and early 2000 super dutys. This has a rating of 5000lb and is kinda like a Dana 60 for the outers and a Dana 44 for the ring and pinion (not exactly but close enough)

Yes this would take some work to get it under your truck. You either have to change the lengths of the axle tubes or move your springs outboard of the frame but these can be found for fairly cheep and would be a good compromise between cost and weight rating for the new motor.

That being said, I have a 2003 (leaf spring axle) and a 2006 (coil spring axle) dana 60's for sale (I'm in Bothell, Wa) PM me if you are interested.

 

If you do decide to go with a 60 there's three of them on eBay right now...one in PA, one in MA, and another in KS. Prices are $1200-$1500

 

What is "an incredible rate"?

 

If you ask for specifics like that, I have to go look things up.

I started driving the swap in April of 2013, I replaced ball joints as I was doing the swap when I was waiting for some parts.

I inspect the vehicle every January, and I've replaced them in 2014 and 2015 because of looseness.

So that's 3 times since the install.

 

How many miles and under what use?

Towing/hauling...or getting to and from work?


I am surprised at that amount.

 

I think it's the parts you are using. I've been driving my Cummins powered 77 F-250 on the dana 44 front axle since the summer of 2010 and still have not had any issues with ball joints or anything else.