are all dana 60 carriers the same threw the years including makes? For example, will a carrier out of a mid 80to late 90's dodge fit in a early 77 F250? Thanks.

 

D44-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.

This is else where on FTE if you look into the Read First threads. lol

 

Thanks Rich but maybe i didnt explain it right. All im changing is the carrier in the Dana 60 in the rear axle. My cross pin that holds the spider gears has been loose due to the roll pin broke and the holes in the carrier holes are long gated,BAD. Im not going to change the whole housing. My buddy has a newer one i can take the carrier out of,but i dont want to tear it apart to find out there different, i just found a 60 out of a 78 ford 3/4 ton for $100. I may go get that one and just pull the carrier out of that cause i know there the same,i know i'll have to set the lash which thats no problem.

 

Oh ok that 100 buck one sounds like a deal then.

 

i agree,i think im just gonna go get it tomorrow and be done with it. The housing is complete with brakes and everything. THANKS Bud

 

No Dana has a carrier, what you want is the case (4204 or 4205 in left parts catalog pic).

A carrier (4141 in right pic) will only be found with Ford 8 & 9 inch rear axles.

TWO different Dana 60 cases: The one used with 4.56 and 4.88 ratios is different.

The cases used with Limited Slip (not pictured) are different than without.