I've read a couple articles on swapping a D60 into the 1/2 ton trucks and broncos. Sounds like a fairly straight forward modification, but Murphy's law would tell me that something will be problematic.
Has anyone here done this swap? Are there negatives such as steering issues, or any clearnace problems?
I have a line on matching 1979 D60's with 4.10 ratios for $600... feel like I can't let this deal get away, but dont want to spend the money if I can't use them.
This is a fairly easy and straight foward swap.
You have found the best and most desireable front axle possible. The 78/9 front dana 60 has the longest short side axle tube available, and provides the easiest swap with the least amount of modifications.
Suggesting that you contunue to use the front coil spring suspension, and purchase a set of axle "wedges" to weld on. This provides a mounting point for your stock or aftermarket radius arms.
Next would be to make a bracket for the trac bar, but again if you can handle welding the wedges, this should be a snap.
Steering is another small issue, and determining which style is more or less based upon the amount of lift that you will use.
The important part here is keeping the trac bar, and the drag link parallel.
You will have to make some driveline modifications since the d60 is larger in diameter, it will require a shorter front d-shaft.
Brake lines will require a little modification. The 60 and the 44 use a slightly different routing configuration, but again, not a deal breaker.
Rear axles are super simple since you do not have any steering to worry about.
You will have slight driveleing and possible u-joint issues to overcome, but is easy as pie.
The rest is just the labor required to get that thing in there.
I have performed this on a few 1/2 ton trucks, and a current Bronco.
If you can justify the use of a larger drivetrain, you may consider not using the rear 60. These are 30 spline units with rather small shafts. They are reasnobly tough, but not much more than a D44, and marginally stronger than the 9er that you are replacing.
Some 70's, sterlings, and even the GM 14 bolt full floater would make a much stronger candidate.
Either way, unless you modify the hubs, these will be 8 lug, and require different wheels.
I knew the front axle was sought after, and definitely happy to get it at a reasonable price. High fuel prices have people selling their truck parts / projects like hotcakes in my neck of the woods.
Can you tell me where I can purchase the wedges? I was planning to buy a donor 73-77 D44 to get wedgies, but would prefer to just purchase them if possible. I read that my '78 D44 has cast wedges which wont work for the swap.
My truck will have at least 6" lift, so maybe the driveshaft length will work, and I will only have to change the slip yokes to match the larger diff yokes. I can work through it.
FYI... the axles come with 16.5 x 10 aluminum slot wheels. Not big on the 16.5's, but I dig the nostalgic look of the deep offset slots!
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look in my gallery, I have some pics and descriptions on how I did mine.
__________________ '77 F-150 short bed,Dana 60 front factory coil spring suspension,Dana 60 rear 4.10 gears,460 with Holley 750, L&L fenderwell headers,150 shot NOS, ZF 5 speed trans,205 transfer case twin stick conversion,35 inch Boggers,sand scoops for the rear,onboard air,stainless Magnaflow exhaust
Thanks for all the info... I feel comfortable with making the modifications for the swap, but not sure if I want to drop the loot right now.
I checked out the axles yesterday... looks like the front will at least need the lockouts replaced. I was a little disapointed that the front was an open diff. My 44 is factory limited slip.
Does anyone have a feeling for how much I could get for my D44 and 9"? Both have factory limited slip diffs. Wondering how much $ I will be able to recoupe. Seems like the truck parts are harder to sell now that gas prices have gone up.
you should be able to get 300-500 out of your 44/9 combo. you need to snag those 60s though because that is only about half of what they should be goin for
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Just another zombie.
my rig:
09 f-150 6" body lift, TTB front,stacked rear blocks,BFG A/T, Fuzzy Dice
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