There are a few changes in axle choices and specs for 2005.

The 2005 Dana 60 and Super 60 have an axle shaft minimum diameter of 1.356", and 1.47" diameter over the splines with 35 splines. Again, the D60 for F250, F350SRW and F350DRW is rated at 6000lbs while the D S60 for the f450 and F550 is rated at 7000 lbs.

Compare that to the 2003 (2004 and before) Dana 60's with an axle shaft minimum diameter of 1.59", and 1.30" diameter over the splines with 30 splines. The D60 for the F250, F350 SRW and DRW was rated at 5200lbs while the D60 for the F450 and F550 was rated at 6000 lbs.

The rear axle ratings also took a pretty good hit. The choices are a little different too.

In 2003, we had 6 axle "choices" :

1) Visteon 10.5" rated at 6830lbs for the F250/F350 SRW
2) Visteon 10.5" dually rated at 8250lbs for F350 DRW pickup w/ 5.4L
3) Visteon 10.5" dually rated at 9750 lbs for F350 DRW Chassis Cab w/ 5.4L
4) Dana 80 rated at 11,000 lbs for the F350 DRW w/ 6.0L and 6.8L and F450's
5) Dana S110 rated at 13,500lbs for F550's.
6) Dana S110 rated at 14,500 lbs for F550's w/ 22,000lbs GVWR

Now, for 2005, there's 7 different axle rating choices:

1) Visteon 10.5" rated at 6200 lbs for F250's (what??? that can't be right!)
2) Visteon 10.5" rated at 7280 lbs for F350 SRW's (Que??? No cano be-o el correcto!)
3) Visteon Dually 10.5" rated at 9750lbs for F350 DRW w/5.4L Chassis Cab
4) Dana 80 rated at 9750 Lbs for F350 DRW Chassis Cab with 6.0L and 6.8L
5) Dana 80 rated at 9000 lbs for F350 DRW pickups (No shizzle for my duallizzle????)
6) Dana S110 rated at 12,000 lbs for F450's
7) Dana S110 rated at 13,660 lbs for F550's

The ring gear sizes, axle shaft minor and major diameter and spline count in 2003 were:

Visteon: 10.5" / 1.36" / 1.50" / 35
Dana 80: 11.25" / 1.50" / 1.57" / 37
Dana S110: 14.38" / 1.72 / 1.85" / 36

The ring gear sizes, axle shaft minor and major diameter and spline count in 2005 are:

Visteon: 10.5" / 1.36" / 1.50" / 35
Dana 80: 11.25" / 1.50" / 1.57" / 37
Dana S110: 11.8" / 1.72 / 1.85" / 34

So only the S110 changes here. (Not for the better, numerically at least)

The Visteon axle is still setup with a 2-pinion carrier (side gears) for the 5.4L (all configs) and 6.8L reg cabs while all other configs get the 3-pinion carrier, same as before.

Hard to believe these figures are corrects but since they are taken from Ford's own BBA books, they "should" be.