Just curious as to what problems I may run into if I decide to swap in a 10.25. My current D60 should do me fine, I just want an easier time to get to the drum brakes Also, what years can I find a 10.25 with out a ABS sensor hole, if any year was offered with out one.

 

I believe a pre 93 10.25" would be the area you would want to look for to have a case without the hole... But i dont think its really a big deal. I just put a 10.5" from a 01 pooperduty in mine with the sensor still in it, no tone ring, but still, no worries. Im not tooooo sure how long the snout is on that D60 you have, but i know when you start swapping out the smaller diffs, you have to shorten the drive shaft for sure, I did with the 9" i had in my 79.
Brian

 

i am looking at doing the same project but i am going to install a f-150 rear end with disc brakes from a 03 f-150

 

Cool, what about U-joints? Did Ford use the same U-joint for each weight class, or did they change U-joint size regularly? Are spring perches different widths?

 

I think the U-Joints stayed the same on the heavy duty axle with the exception of switching between gas and diesel powered axles. The original 10.25 axle that came on my truck stock had U-bolts to hold the U-joint in place, now the truck has a newer 10.25 with lim. slip and it must have been off a diesel because it has the strap style to hold the U-joint in place and I had to get a conversion joint to hold it all together correctly.
Mike

 

hey franken truck i'm bout 1 hr west of you get a newer sterling with discs loose a bit of weight and ovcourse a 10.25 is stronger for obvious reasons over a 9.75 d60

 

Curiosity peaked, PM sent.

 

97/98 had optional disk brakes, but good luck finding those i would assume. You could go newer, 10.5" which is really the same diff all in all. I have disks on mine, but its superduty, so metric lug pattern. Easilly converted with an adapter.

Brian