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Personally, I wouldn't bother playing with the 60 at all, a 70 at the least is the place to start, but, I really like my Sterlings, axles are 1.5" diameter, 35 spline. Sure, the diff is huge, but, I'd rather need a tug because the diff was holding me back than have to limp home on a broken rear. There's more than one mud trail around here that has a rut down the middle from me hammering it through ruts from 33's with my street tires on(31's)... LOL
that's EXACTLY what i have always thought! hell they make winches for a reason
I thought about the D60 for my daily driver but went with the hybrid 8.8 instead. For a dedicated Monster rig etc., go with a 70 or D80/70 hybrid. I have pondered the use of one of the Dana 80 with 70 tubes from a Dodgie 2500.
D70's are easy to trim if you want more ground clearance. I took almost an inch off the bottom of mine and it really doesn't hang much more than the D60. I can get exact measurements later in the week. If you can find a D70U it's got a smooth bottom and a ton of clearance. Check old vans for these. 14 bolts are major trench diggers which is why I'd never use one. Sterlings are a good axle but you don't have near as many options in terms of lockers and gears as you do with a 70. Make sure you can get the options you want before you get the axle. Also, it wouldn't be a bad idea to lay a bead between the housing and axle tube as they have a reputation of spinning the tubes.
D60's can be upgraded to 35 spline 1.5" axles for relatively cheap (it is alright to open up the spindle for a 1.5" shaft) but then your weak point is the ring gear. If I remember right the D70's ring gear is 3/4" larger. I'd really recommend keeping an eye out for a 70U. This is what I was looking for but couldn't find one locally so I went with the regular D70 and shaved it. Took about an hour with a sawzall and a grinder.
Yeah the thing is that i have a 60 (with 4.10's) in the truck i'm using for the sas on my 81, and i was going to be buying a spool for it and i thought that it would be nice to have some little extra assurance with 35 spline shafts in the mud pits, but i think that i will use the 60 with 4.10's weld her up, and unless i can find a sterling (wonder if my dad would miss the one underneth his 87 1 ton, lol) or a 70 (i have to check on a spare full float axle I have to see if its a 60 or a 70), then i will put a locker, 4.10's if it doesn't already have them.
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