solid axel swap
Senior User
Joined: Apr 2002
Posts: 155
Likes: 0
From: KC Metro
solid axel swap
Dana 60 is a generally leaf sprung axle from F-250 and 350 truck fronts, so it requires a little more work because you have to get a hold of a leaf sprung 44 and swap the spring perches and weld them to the Dana 60 axle. If you are planning on swapping a Dana 60 in the front, you should probably put a 60 or 70 in the rear and get rid of the stocker.
-Pentekno2
-Pentekno2
Junior User
Joined: May 2003
Posts: 74
Likes: 0
From: Charlotte, NC
solid axel swap
Broncograveyard.com carries a conversion kit to make things easier on the swap. I would go with the 60 ever thou it does require more work. I think you will be happier with the 60.
Trending Topics
Senior User
Joined: Apr 2002
Posts: 155
Likes: 0
From: KC Metro
solid axel swap
With a Bronco like that you pretty much HAVE to use coils, using leaf springs is barely even an option - thats why were telling you about conversion kits and all the stuff you have to do to prep a Dana 60 to go under the front of your Coil sprung truck. A 44 would be the easiest to get a hold of, but I agree, a 60 is better off as an axle.
If you just HAVE to have leaf springs front and rear, your best shot would be to take an F-250, chop the frame down, and figure out how to get a bronco on it. This has been done a few times, as you can see on Projectbronco.com and with a guy named Trey's "Super Bronco". I would post a link to the site if I was on my home computer, but im on my sisters laptop currently.
Now, I think this would be entirely too much work and the results you would get from it would not nearly be worth the hassel of all of the work. So I would recommend just taking the advice from the guys on this site. They know quite a little bit about Ford Trucks and whatnot. Good luck and have fun!
-Pentekno2
If you just HAVE to have leaf springs front and rear, your best shot would be to take an F-250, chop the frame down, and figure out how to get a bronco on it. This has been done a few times, as you can see on Projectbronco.com and with a guy named Trey's "Super Bronco". I would post a link to the site if I was on my home computer, but im on my sisters laptop currently.
Now, I think this would be entirely too much work and the results you would get from it would not nearly be worth the hassel of all of the work. So I would recommend just taking the advice from the guys on this site. They know quite a little bit about Ford Trucks and whatnot. Good luck and have fun!
-Pentekno2
FTE Stories
Ford Trucks for Ford Truck Enthusiasts
3 Best / 3 Worst Parts of Modern Ford Ownership
Brett Foote
10 Amazing Upgrades That Solve Common Ford Truck Owner Headaches
Pouria Savadkouei
Every 2026 Ford Engine Explained
Brett Foote
10 Ugly Ford Trucks That We Still Kinda Love
Joe Kucinski
10 Things Every Truck Owner NEEDS (2026 Edition)
Michael S. Palmer
Rezvani's Latest Post-Apocalyptic Monster Is a Ford F-150 Raptor Underneath
Verdad Gallardo
Top 10 Most Expensive Ford Trucks Ever Sold on Bring a Trailer
Joe Kucinski
2027 Ford Super Duty Buyer's Guide (Every Model, Engine, & Package)
Brett Foote
Top 10 Ford Truck Tragedies
Joe Kucinski
Junior User
Joined: Jun 2003
Posts: 78
Likes: 0
From: Long Island , NY
solid axel swap
Well my advise being that I have a bit of experience on this matter is .
1 - Stay away from the Fabritech SAS conversion from JBG , it
is not at all worth the money .
2 - A leaf spung D60 is not that hard to install , you just need to
be a good welder/fabricator .
3 - D60's are only foung in F350 untill the late 80's . The new
D60 axle's are not worth the trouble They have a metric lug
pattern and the use ball joints like the D44 .
Your best bet is to go to the junk yard for about $300 or so and getting a D44 with the radius arms . The only real fabrication needed is a Trac arm mount and the radius arm mounts . The simplest way I have done the radius arm mounts was a piece of angle iron and a good gusset and they will be solid . Or you can build something like mine which takes a little more figuring and welding . Check out my SFO site in my sig line there are some good pics of the SAS conversion .
1 - Stay away from the Fabritech SAS conversion from JBG , it
is not at all worth the money .
2 - A leaf spung D60 is not that hard to install , you just need to
be a good welder/fabricator .
3 - D60's are only foung in F350 untill the late 80's . The new
D60 axle's are not worth the trouble They have a metric lug
pattern and the use ball joints like the D44 .
Your best bet is to go to the junk yard for about $300 or so and getting a D44 with the radius arms . The only real fabrication needed is a Trac arm mount and the radius arm mounts . The simplest way I have done the radius arm mounts was a piece of angle iron and a good gusset and they will be solid . Or you can build something like mine which takes a little more figuring and welding . Check out my SFO site in my sig line there are some good pics of the SAS conversion .
Junior User
Joined: Jan 2001
Posts: 81
Likes: 0
solid axel swap
I have a D60 in front and a 10.25 in the rear of my 1994 Bronco. It was not that bad to install. Especially if you have a 1991 or older Bronco. The newer Broncos have 'energy absorbing" frames in front that will not easily bolt to F350 suspension parts. I used a 1989 Bronco frame.
The front leaf spring mounts from a F350 can be bolted up to the bronco frame. You'll need to drill and chisel off a bunch of rivets. The front spring mount require a 1/2" spacer to compensate for the 1/2" recess in the F350 frame. The job is easier if you have a donor F350. I used 1/2" grade 8 bolts to bolt in the F350 spring mounts. No welding required.
The swap gives about a 4" lift over the stock TTB IFS.
John
http://home.mn.rr.com/doodle/chassis.html
1994 Bronco
1989 Bronco frame
1992 D60 4.10 Power Lock, 10.25 Traction Lok
1992 EFI 7.5L with mass air(not speed density),
1977 C-6 & NP205 (using short 5 3/4 adapter)
305 70R 16 Goodyears
The front leaf spring mounts from a F350 can be bolted up to the bronco frame. You'll need to drill and chisel off a bunch of rivets. The front spring mount require a 1/2" spacer to compensate for the 1/2" recess in the F350 frame. The job is easier if you have a donor F350. I used 1/2" grade 8 bolts to bolt in the F350 spring mounts. No welding required.
The swap gives about a 4" lift over the stock TTB IFS.
John
http://home.mn.rr.com/doodle/chassis.html
1994 Bronco
1989 Bronco frame
1992 D60 4.10 Power Lock, 10.25 Traction Lok
1992 EFI 7.5L with mass air(not speed density),
1977 C-6 & NP205 (using short 5 3/4 adapter)
305 70R 16 Goodyears
