Dana 60 swap
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5th Wheeling
Joined: Oct 2014
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Dana 60 swap
I am buying a 97 f-250 4×4 5 speed next week that was slightly wreaked. The front axle is bent and since I hate ttb axles anyways I figured I would throw a d60 under. I have never done this swap but I hear I is pretty simple. My biggest question. Are the leaf springs different? Are the drive shafts different? Are there any tricks that make this swap easier? Any other tips or suggestions greatly appreciated
Posting Guru
Joined: Aug 2007
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From: Cato Arkansas
The leaf springs are different load ratings I believe but will bolt up the drive shafts are different. My f250 shaft bolted in but it's not ideal since it doesn't have the double Cardon joint in it. I'm in the process of getting a flange for the t case and a 1350 yoke for the d60 so I can use a super duty shaft
Cargo Master
Joined: Nov 2006
Posts: 2,171
Likes: 20
From: Denton, TX
What ark redneck said about the yoke and drive shaft.
Swap over the F350 pitman arm otherwise your U turn ability will be reduced.
Leaf springs are different, the F250 springs are stiffer due to the TTB. Replace them with the F350 springs. Replace your spring and pivot bushings now while it is easy.
Prep work items like longer brake lines, sourcing your replacement (if needed) F350 tie rods, collecting needed hardware for the track bar bracket, new U bolts, and servicing of the D60 hubs are all good time savers before swap day.
There are a number of pictures in the thread in my signature file that may be of some use.
Good luck!
Swap over the F350 pitman arm otherwise your U turn ability will be reduced.
Leaf springs are different, the F250 springs are stiffer due to the TTB. Replace them with the F350 springs. Replace your spring and pivot bushings now while it is easy.
Prep work items like longer brake lines, sourcing your replacement (if needed) F350 tie rods, collecting needed hardware for the track bar bracket, new U bolts, and servicing of the D60 hubs are all good time savers before swap day.
There are a number of pictures in the thread in my signature file that may be of some use.
Good luck!
Last edited by tjc transport; Nov 2, 2014 at 07:12 AM. Reason: correcting a typo.. Tom
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5th Wheeling
Joined: Oct 2014
Posts: 32
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Great write up on the d60 I will be using it for sure. The truck I am getting already has a 4 inch straight pipe and air intake. What would you guys say the next best thing is to do to help wake up the motor, bigger injectors, bigger turbo, ect ect......
i ain't rite
Joined: Mar 2005
Posts: 65,515
Likes: 5,567
From: Marlboro Mental Hospital.
What ark redneck said about the yoke and drive shaft.
Swap over the F350 pitman arm otherwise your U turn ability will be reduced.
Leaf springs are different, the F250 springs are stiffer due to the TTB. Replace them with the F350 springs. Replace your spring and pivot bushings now while it is easy.
Prep work items like longer brake lines, sourcing your replacement (if needed) F350 tie rods, collecting needed hardware for the track bar bracket, new U bolts, and servicing of the D60 hubs are all good time savers before swap day.
There are a number of pictures in the thread in my signature file that may be of some use.
Good luck!
Swap over the F350 pitman arm otherwise your U turn ability will be reduced.
Leaf springs are different, the F250 springs are stiffer due to the TTB. Replace them with the F350 springs. Replace your spring and pivot bushings now while it is easy.
Prep work items like longer brake lines, sourcing your replacement (if needed) F350 tie rods, collecting needed hardware for the track bar bracket, new U bolts, and servicing of the D60 hubs are all good time savers before swap day.
There are a number of pictures in the thread in my signature file that may be of some use.
Good luck!
use the complete F-350 steering components. they are different from the TTB stuff used on the F-250.
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5th Wheeling
Joined: Oct 2014
Posts: 32
Likes: 2
Since I am not having any luck finding a d60 for a reasonable price I am thinking of rebuilding the d50 for now. The left portion of the axle is bent and needs replaced. I found an axle housing that contains the difference cover. I have never rebuilt one of these before, is it pretty straight forward bolt together setup. It seems like the last time I took one out (about 4 years ago) there was something that was confusing, or different to work one. Any good tips for replacing the driver side of the d50
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Posting Guru
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Cargo Master
Joined: Nov 2006
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From: Denton, TX
Thanks for keeping things clear!
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