Dana 60 Conversion

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Sep 30, 2025 | 08:28 PM

FordFrickenf100

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Dana 60 Conversion

Recently, I acquired a Dana 60 rear axle from a donor 1972 F100, and I'm looking to swap my existing standard 9in rear axle. Since sizing it up, I noticed that the driveshaft size may be a bit different. I've also seen some posts suggesting I find an F250 or F350 axle and install it, but I'm not sure that the length would work. For context, my truck is a 1971 F100 full size with the 360FE and C6 auto trans. Looking for any help possible!

Oct 1, 2025 | 09:19 AM

Crop Duster

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From: Tri Cities, TN

My question is why you are wanting to go to a Dana 60? The Ford 9 inch has more parts availability than any other rear axle ever produced and is more than strong enough for an F100 with a 360. The Dana's can be expensive to repair and have carrier differences depending on the ratio. The F150 will have 5 X 51/2-wheel bolt pattern the F250/350 will not.

Oct 1, 2025 | 12:16 PM

blue68f100

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From: Piney Woods of East Texas

The std 28 spline axles that came in these trucks are good to around 350 hp. If you happen to have a 32 spline your good to 550 hp. Now with some upgrades (nodular cast case and 1.5" 35 spline axles) it good to 1000hp. The beauty of these is the ease of changing on out if you ever need too. You just pull the axles, remove the 10 nuts holding the 3rd member in and it's out.

Oct 1, 2025 | 06:38 PM

Green72F250

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From: Colorado Springs

Does your Dana 60 have 5-wheel lugs for the F100? If so, that is a rare differential, as the F250/F350 Dana's have 8 lugs. The Dana 60 for the F100 was an option.

Oct 1, 2025 | 11:04 PM

RichS2659

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From: North Pole, Alaska

It probably is a 5 lug Dana 60.3 semi-floating axle which is just like the 9". The 8 lug Dana 60 is a full-floating axle. Basically the only thing that is the same is the differential which has a 9 3/4" ring gear..

Oct 2, 2025 | 03:30 PM

FordFrickenf100

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Quote:

Originally Posted by Green72F250

Does your Dana 60 have 5-wheel lugs for the F100? If so, that is a rare differential, as the F250/F350 Dana's have 8 lugs. The Dana 60 for the F100 was an option.

I’ve actually never heard of that, but in this case it’s an 8 lug one. It came as a 4x4 conversion from a donor 71 f100 but I want to keep mine a 2x4 if possible. I just wanted to upgrade the rear axle to be more heavy duty and include the F250 springs.

Last edited by FordFrickenf100; Oct 2, 2025 at 09:23 PM.

Oct 2, 2025 | 03:33 PM

FordFrickenf100

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Quote:

Originally Posted by RichS2659

Currently I have a 3.73 ford 9” axle that came with mine from the factory. There’s a lot more that came from the dot vehicle that wasn’t originally 4x4 (I.e. 390 w/4x4 NP235, divorced transfer case, Dana 60 front, steering box, etc…)

Last edited by FordFrickenf100; Oct 2, 2025 at 09:23 PM.

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Oct 6, 2025 | 02:54 PM

RichS2659

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From: North Pole, Alaska

It sounds like the donor 4wd conversion stuff is from a Dent. For the rear springs, did they use the donor F-250 springs, or the original F-100 springs? If it is a Dent, I think the rear springs might be wider and longer than the 67-72 bump springs. Are your original F-100 springs regular or Flexo-matic springs? It does make a difference. I am very familiar with this spring swap as I converted my 72 F-100 Flexo springs to F-250 Flexo springs back in 1979 to make an F-150. It did make a big difference in cornering. I once held off a Vette on a very curvy state highway for 25 miles before we hit a long straight stretch where he could pass me.

Oct 13, 2025 | 08:38 PM

#10

FordFrickenf100

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Quote:

Originally Posted by RichS2659

I’m not sure but I think the front springs are for a 100 with 4x4 and the rear are for 250’s but I’m not sure if they’re standard or flex. It came off a 2x4 original truck they converted to 4x4. I honestly wanted to do the springs as well with 250’s but I know the length is different and would need a plate welded. If I added the dana 60 and kept the transmission, where could I source the w flex springs? Also I could just put larger tires in the rear as well to help with anything off road and smaller tires in the front

Oct 14, 2025 | 12:30 AM

#11

RichS2659

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From: North Pole, Alaska

You do know with the D60, you will have 2 different wheel sizes to deal with. What are you expected to haul with a D60? A 9" is more than capable to haul heavy loads, but not on the same scale as a D60 and a F-250 frame.
Here are 67-72 regular springs:
https://www.fordification.com/tech/i...100-noflex.jpg
Here are 68-72 flex-o-matic springs:
https://www.fordification.com/tech/i...f100-wflex.jpg
They are longer than the regular springs. What kind of springs do you have now? Also measure the width of your present springs and compare them to the F-250 springs. Your best bet is to visit a JY and get the same type of 67/68-F-250 springs that you presently have. Save yourself the trouble with unknown type of springs and having 2 different wheel systems, unless you change the front to 8 lug also. But you still have an F-100 frame which is still plenty strong.